Drifting - slightly - I'm currious about the following...
I was thinking about routing off the sharp edges of exposed vertical
and diagional
members. Now this would be for edges not in contact with skin or
gussets.
Maybe 1/8 or 3/16 radius router.

And I'd not try it on longerons (chicken).

But rounding off the square edges of the wood seems like a reasonable
weight reduction idea.

Ok, maybe it's just a few ounces involved, but -
1) reducing is mo better than adding
2) the squared off edges don't carry much - if any - load.
3) rounded edges are less susceptible to damage (splinters?)

Comments?

Richard