Everything I knew has been filtered through what I've learned here.
I agree that aerohead's baby Template could be built with welding rod. The reflex curves on your aerocap are a different case. Your solution is fit for purpose.
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How much would such a geodesic 1/4 dome weight in lbs made of 1/2 .095 round =.41lb/ft bair ,strong enough to hold out a road closing snow storm in the Sierra Nevada(10+feet in lessthan 6hrs.) I'm at 35lbs wraped
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The theory with geodesic domes is that the size of the structure and the size of framing members is uncoupled; i.e., you could built a garage for that truck out of toothpicks. And they enclose space with the most economy, so I would say —potentially— less.
Faucets vs facets
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the math required to do that by hand is beyond me...
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Me too, it's not complex but it would be mind-numbingly repetitive to do it by hand. It was all done graphically, taking a 6v geodesic sphere and stretching it asymmetrically in two directions. Which was then sub-divided by the program (Wings 3D) to get the hexagonal overlay. So now I can point to any edge and get the length and endpoints in space just for asking.
What you did with the aerocap is more similar to my experiments with boat tailing a VW Beetle. I used 16' lengths of redwood bender board to find the correct curves from a point in the front to a vertical line in the rear.
I built it to look at it (it could be truncated at either of the two bulkheads) and then tore it down to recycle the redwood strips. I'm currently looking at used aluminum tubing to replicate it.