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Neil,
Here are some photos of my X-Prize car beginnings. Have you tried to straighten out the leaf blower airflow using stacks of tubing, as Mythbusters did with the boxes of straws? The white rectangular tube in the photo is that "pultruded" fiberglass I had mentioned. I was thinking, to make fast body modifications without having to use fiberglass to smooth the foam, perhaps you could use shrink wrap, as long as it didn't melt your foam!
Chuck
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