[NeilBlanchard]

Those jaggies are not hard to cut out. I spent months doing drafting work and even to go to 1" layers would have doubled the drafting time. Half inch layers would have quadrupled the drafting time and doubled the cutting and gluing time.

If I do it again, I'll model a "box" on the inside made from the aluminum honeycomb composite panels, and then glue foam only on the outside. Basically exactly what the folks building the Trev did.