It's fairly obvious to me that I will end up building flat panels
and seaming them.   One has to use the techniques of intelligent
infusion intelligently, and a complex mold is not intelligent when it
serves no real purpose.  What I am toying with is how one creates a
"rebate" for a flush seam.  The foam would seem to need to be milled
down on both pieces, the thickness of the finished fiberglass used for
the seam..... on the outside, before infusing.  Has anybody done this? 
What equipment was used?  I would presume that a hand held power planer
would be the culprit here. Controlling it might be an interesting
challenge.

    Also in weight estimates, I've been assuming that using infusion,
one should be able to hit 1:1 by weight of resin and glass.  This seems
perhaps optimistic.  What kind of real world numbers are people seeing? 
I assume that 240gsm will finish out at 480gsm.....

                                                H.W.