@Rob:

Looked at the blogs and will look again.  I think i have some idea on process..  I am kicking around the idea of vlogging this build form the 'eyes of a novice' as I think it would be helpful.

The payload question for ele got missed :P  So here that is again. 

So 2-3 people is probably fine then I think.  I keep trying to aim smaller for the first go as I keep thinking about things.  That said how does it handle 2-3 people, but just have 352 lbs payload?  Maybe that is supposed to be kg payload?  Or, are those just some really light people?  Or is that 2-3 people plus 352 lbs? 

Optimization wise?  Would cutting on 3 axis CNC Maslow help?  I notice that CNC cutting was mentioned in the build blog for foam and the Exhilerator.  Assuming of course I can get it cut accurately enough across the entire surface for mdf molds or foam?   At worst, I can be doing some other task, like actual 'work' work from home.  Doubling up and being 'paid' to build is always good.  But, are there other savings in doing something like this?  I.e. mold pieces are easier to assemble/setup accurately or whatever? 

@All

Sail plan:

So right now I am 'defaulting' to schooner.  Hopefully, Rob will have the soft wing sail sorted but if not, then not.  Now, like some others, I came here from considering Junk rigs, specifically both the aero rig and split rig were on my top picks list.  The split rig caught my eye in that there was an account were it provided enough lift vs drag (presumably this is why) to actually 'counter' heel in some cases.  I.e. boat heels toward the windward, which must have been an interesting thing for other boats to see.  But the key here is could such as setup provide a larger SA/D safely given JR can reef easy-peasey?  Or, are junk rigs simply a no-no on HPs due to shunting or some such?  I think I will drop this by JRA forum as well to see what they think.

​Nothing wrong with junk rigs on harrys.  The traditional ones will not perform any better than they do on other boats.  The latest advances are well worth looking at, but keeping the weight down is an issue.  

The soft wing is progressing.  Took longer to get the fairing section built from a flat sheet than i thought it would.  Ended up with a bent flat sheet, which works well.  Also rethought the shaping mechanism and luff tension.   I've had a bit on with the cargo ferry and general design work, but with a bit of luck, I will put the first fairing and the sail on the mast next week and see how it looks.  El rudders finally finished ​and look like they will work.  Tow test tomorrow, maybe a kite run as well.