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Shingled lap joint?
Once again I'd like to see failure modes, as in 'popped like a grape'.
I have access to an hand-operated roller/shear/brake with an 18" lever arm. I stopped on the roller at a 12" radius, but I could have kept going. Shearing was adequate. When I tried to brake a 90° angle, it popped the skin on the outside. A score or shallow saw cut on the inside is indicated. With a router I could rabbet opposing side of a join and create a half-lap. That would be awesome. Also for counterboring holes for through-fasteners but it would take more hand-waving to explain that. Needs pictures.
Back on the subject of the Template. You can un-peel those geodesics and get basically gores with darts. Also needs pictures.
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