Well Herr Fisher!
that really is quite something !
...==> of all your trials and tribulations, and all the trial and error-- the point that stands out, to me especially ,
for all of us to learn from ...
is that sometimes measuring is no longer the ultimate datum method.--
but making templates and patterns is.
I make a lot of templates and patterns ( even in model making eg Normandie decks for example...! )
But in my 1/1 scale ( small ) business --
I have made many thousands of sometimes HUGE templates
We produce complex multi-part multi-function three dimensional fabric structures
( Boat covers and canopies for motor and sailboats
These range from 15 feet to 130 ft plus
The process is further complicated by the fact that
fabric stretches different amounts , in different directions relative to the woven pattern
under differing amounts of tension , from different directions
As far as I have been able to ascertain in the last 30 years (!!!),
the structures we produce are un-measurable (
in a non-digital way )
and as such every cover we build is individually templated / patterned.
Its results that count....
Our canopies are far more beautiful in their 3-D shapes with totally flat, crease free but 3-D shaped windows ...
than the
"" digitally designed . measured, plotter cut and remotely assembled "" covers of some of our competitors ...
(whose products often feature gawky lines and rippled windows!!

)
I do not dispute that in time, they will eclipse and overtake dinosaurs like my self...
But I take heart that Stonehenge, HMS Victory, The Pyramids, the Grand Cathedrals and the Model T Ford et al
were created without digital design.
... and in some instances, like wooden ships and Cathedrals --on site--often by eye , and not measurements
So Daniel-- do please continue on and make paper templates, stabbed with scalpel blades
and build your (

near ) perfect analogue model with ( fortunately ) dimensionally predictable materials!
Jim B ( Luddite Dinosaur )