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kach22i's concept is beautiful and goes well with this velo.
I built my custom design out of coroplast in the kitchen of a former apartment I lived at. There was minimal mess. Working in a tight space was not easy, but it was doable.
Regarding rear wheel and derailleur/chain clearances, it would be best to make a prototype frame of the shell's attachment points first, before making the actual shell itself. That way, you can test for rubbing and clearances before going through all the labor of making a full shell, and if it doesn't work, you can modify it into something that does work. Get a basic frame design for the tail down that you know will work after testing it,THEN build the tail around it. Stiffening the rear of the frame is always going to be needed, given how much bicycle parts like to flex.
I ran into this same issue with the rear wheel cowling of my tail section.
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