I talked to Hans about this too. About using lexan and forming it. He told me he had tried to do that too... but even lexan broke. The rudders themselves are foam cores with lamination. The metal parts are easy enough to construct, the glassing has to be done under vacuum to get that really complete bond.

The eleven hundred is not a bad price considering the aluminum welding and glassing. I bought just the glassed rudder from him for a hundred. Metal not included. He wanted 200... he will negociate.