In some sense I am competing with myself to realize the cheapest, quickly made,
servicable full fairing. EMT, zip ties, coroplast, corrugated cardboard, paper-mache, small wood blocks, and industrial velcro properly mixed together seems the lowest dollar solution.
I am very open to suggestions on how to lower development costs and speed iterations. So please do continue to comment and help move this along.
A simple method of waterproofing paper, which also strengthens it, was amply demonstrated by the founder of
Cardboard Technologies. Something similar may come into play in this thread.