This is a great idea. My request is that you
consider a geodesic construction. It can be laid out as a flat pattern with darts and cut from a single sheet. That will self-assembly into an accurate surface. Much less work.
http://starship-enterprises.net/files/3f%20icosa%20Peel%20Pattern.jpg
I can provide all the relevant edge lengths for a prolated ellipsoid.
'What do you think, sirs?'