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gap closure
I'm pretty much set on using composites. Once out of the autoclave, de-bagged, and through a trim fixture, they'd essentially be ready for assembly, requiring no additional processing.
There's already a market for new product, from recycled composite refuse.
Low mass is the target. 4.321- ounces / square-foot, ovoid, stressed-skin monocoque body, with bonded composite structural hard-points, suspension, wheel, etc..
I don't recognize a better option.
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