Toxictackle

Dan, what kind of wood are you using? When I use balsa I have a router table set up with a round over bit and I glue 3 pieces of wood together before I cut it out on the band- scroll saw . The middle piece of wood is the surface that the guide roller on the router bit rides on while cutting , after you round the edges you remove the middle piece of would witch is held in place by a small amont of superglue, then you put you wire frame and hardware in and touch up any rough spots with a 180 grit sanding sponge . I us to shape them all by hand , but router table gets them very even and does it much faster than all the hand sanding. If you have to do them by hand always sand balsa with the grain of the wood or your wood will looIMG_3171.JPGk and be real fussy and it's harder to seal and get a good paint job. Cut them out where the grain of the wood runs front to rear to get better results.