Flare / Bell Bottom Build, Part 1 Design Process

Drawing up a shroud can be tough, if you are off by the slightest bit the fit will be poor.
I use the shroud tool on www.payloadbay.com for a start.
But, the shroud will have to be printed later with more than one shroud per sheet of card stock.

The shroud was dropped into Corel Draw and redrawn.
Three shrouds were made, one slightly larger another a bit larger.
One of the three should give a friction fit over the BT-5 body.

The lug hole is pre-punched and will be in the kit.
That small hole is hard to cut out after the shroud is formed. By pre-punching the lug hole I'll have a perfectly round top to the lug recess hole.

After the shroud is glued up, the straight vertical lines in the lug slot are cut with scissors.
This keeps the shroud stiffer when forming and gluing. If the lug slot were completely cut out (before forming the shroud) it is harder to get it round on the narrow end.