By now, I have developed a reliable construction method. The rectangular torsion boxes are made from 1/2 in. Birch Ply, 1 1/2 in. rigid foam and 1/4 in. plywood skin. The shoulders also made with 1/2 in Birch web with a curved web every 3 in or so. The drawing and cutting of the curved sections needs to be precise in order to have a exact 90 deg corners and a fair surface after skinning.
The 1/4 in. skin for shoulders is 3/8 'wiggle board' planed down. to dimension. On this project, I will roll on the Unibond-800 for skin-to-web and skin to veneer all a one time. This will save a bunch of time now that I have conifidence in the vacuum clamping of skin to web.
A little polyurethane construction glue and a couple of lag screws pull the parts together. The joints are so tight, I'm tempted to just leave them, but now the inlay has become a design element.
This is how it looks after the lye wash and stain.
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