[skyking]

Originally Posted by jray3

I'd like to build a trailer shell following the template, but with flat panels that are precut to shape, zeppelin-style. Undecided on a riveted aluminum skin vs foam panels to then glass over, or soaking an inflated envelope with resin, then building it up, but am leaning towards aluminum (possibly with a spray-foam interior layer to stiffen and insulate).
So far I've struck out on finding a pattern to scale up. Closest thing is these hot air balloon panels from a crafter's blog (don't laugh if you click through).
http://prudentbaby.com/wp-content/up...ir-balloon.pdf

DIY Hot Air Balloon Mobile (Free Pattern!) | Pretty Prudent

This company gets me close, have requested a design cost estimate....
APEX Balloons - Hot Air Balloon Manufacturer, Hot Air Airships, Balloon Repair Station

Any of you design wizards already cracked this nut?

Graham, eh?
Maybe we need to get together and do some brainstorming. I too have a trailer or two stuck in my brain; my medium is probably going to be XPS foam, shaped and then glass/epoxy.