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While I do agree that a full belly would be very beneficial, that's a bit of work.
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You get my point. There's a lot you can do before you get down to that fine tuning. The rest of the ¶ shows you have a handle on the issues.
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...tuft testing this cap. Is there a set of "rules" to do this...
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One thread had the poster using a bigger square of paint friendly tape and a smaller square of something to hold the yarn to the first piece. I'd add—that could be hot melt glue before you cut a strip of tape into squares.
...and only half the cap needs to be tufted. A grid is a good start, but if you suspect separation, or worse—backflow, use longer yarns. A reconfigurable boom that gives a top rear view means you don't need a chase vehicle, although you could use one as well.
I'd skin it with Polymetal. Think strong as 5/8 plywood and light as coroplast. I haven't done a whole project with it, but I have tested samples. I could shear and roll it, but to brake an edge, I think you'd have to crush it along the line first. A 4x8' sheet is approx. $100 wholesale and $150 retail.