Bumping this old thread as i have been watching these excelent videos full of design and construction details... heres the link
https://youtu.be/U2PX1p7nbw8
Mike uses sandwich construction with foam and fiberglass/epoxy to build this slippery one seat plane, which would transfer to aero caps or covers nicely.
Look up The Arnold Company on you tube. Many excellent vids like "moldless low drag wheelpants"