Hi Jim,
Still following with interest. In fact I went back to page one and started all over again. The CAD stuff and printed parts I still find pretty amazing. Who'd have ever thought only a few years ago that printed parts for modelling, among other things, could become the norm for scratch building.
Your method for making the buck/mould? for vacuum forming the canopy was interesting also. I use a slightly different method. If you go to my BM F8F build, page 1, post 18 &19 it is more or less self explanatory. I use clay (Super Sculpy Firm) for plunge moulding and general pattern making. Pretty versatile material.
I've provided a link that explains why using a certain kind of clear plastic is the ideal kind to use for vacuum forming canopies. Just thought you might be interested.
Cheers
Dennis
http://www.ipmsstockholm.org/magazine/2002/08/stuff_eng_tech_moulding_canopies.htm