Vetter and I are finalizing the placement of key fairings via email today so I will have a better idea where stuff needs to be designed.
I have been looking at the strip built canoe technique specifically in relation to using foam and making recumbent shells. I think this technique would lend itself well to making the tail section.
Now I just need to identify costs associated with going this route versus another. Most people are using a router, a fixed saw of some sort (table or other), and a plotter. I don't have either but I think I can get away with using a wire cutter with a jig for the strips and a straight one for cutting the strips from the large sheets.
As for the plotter I could index the drawings and print them on 11x8.5 pieces of paper and tape them together. I am also going to have to redownload sketchup so I can make the required large plots (assuming it is capable of this if not I will simply use illustrator and math).
But I likely have to wait as I need the rear seat cowl as a starting point and I need to switch focus to getting the bike registered which is going to require mounting lights and some other items I must fabricate. In the mean time I can collect materials like the fiberglass, epoxy resin, tools to apply them, etc.
I also need to figure out my license plate solution on the 'ideal' tail. On the default tail it is going behind the head rest, but on the ideal tail it cannot be there as there will be fiberglass blocking it
If I did the ideal shape and a Kamm tail on it I could easily mount the license plate. But if I did a point at the rear I imagine I would have to cut into said point like others I have seen do. I don't think I am allowed to make a plexiglass cover for the license plate to fill in the cut gap in Virginia / MD / DC.
@Grant-53
I haven't done the math yet but it seems the tail would be extremely long using the 4 percent / 7~8 percent grades, or do you only keep these grades till you reach the ideal length? In my case, given the width this would be 107cm.