Ok, I'm going to weigh in here!

I am a relatively new glider pilot but I have flown power, hang
gliders. I have also been a skydiver. I am now living in Germany and
as I have a glider club 10 minutes from the house, last year I decided
to get my soaring license. I could have used my power ticket o get a
license here in a short time but that (I feel) would have been a
mistake. The differences in the 2 sports go beyond landing,
navigation, and airspace knowledge.

I am also a sailor and have built sailboats commercially. The biggest
gains in efficiency in sailboat production came about from modular
construction. This is being used in the sailplane building process to
some extent.

But!!! The next biggest gain would be in using 2 part molds for the
wings and fuselage. What this means is there is a mold with 2 parts
for the upper wing and 2 parts for the lower wing. This means the wing
skins would have 4 molds (port and starboard). The fuse would have 4
molds (2 port and 2 starboard). This would decrease the amount of
labor involved in each part.

The upper wing mold would include the spar cavity, you would lay the
spar into the inside upper wing mold spar cavity before laying the
wing skin. Using precut/prepreg E glass with Divincell (or other
appropriate) cellular core, you would lay the skin and spray gel coat
on the upper (outer) mold and compress the 2 molds. Using vacuum and
heat to assure proper resin consistency will mitigate voids and
delamination problems.

When the upper wing skin is cured it would be mated with the lower
wing skin (both still in there outer molds) and bonded. The airbrake
module would slide into the laser cut bay in the upper wing with
Kevlar rigging wires (not pushrods). The aileron and the aileron
controls (also Kevlar wire) would be installed.

The fuse would follow the same procedure.

Now, we must build 2-300 of these planes just to break even on the
tooling (not development) so we have to agree on one design,
preferably one already in existence. If we could sell 4-500 units in a
2-3 year time frame then we could (possibly) have a viable business
model.

Sound like an LS4 clone to me!

Bob

(The proceeding is a very opinionated and un-researched scenario)