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Aluminum honecomb panels come in a variety of sizes and dimensions. A sheet of 3/8" x 24" x 48" lists for $162 USD at McMaster-Carr. You can search online for other sources near to your location. Consider using threaded inserts for attachment points and epoxy fillers for edging.
Serrated knives do work great on foam. We used an electric carving knife.
For a military paint job consider the P-51 Redtail fighter planes; bright silver with red rear quarter. Maybe some yellow or amber signage on the nose. This would follow standard running light colors.
I suggest reinforcing the joints at the rear bulkhead by the seat with vertical pieces of 1" aluminum angle stock bonded with epoxy for stiffness.
Looking great!
Last edited by Grant-53; 05-21-2013 at 11:48 AM..
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