Thanks Snoopy. The bulk of the panels are .040 styrene and for the rounded areas I went thinner and heat formed it to shape before attaching. Laminated parts do want to feather on the edge when sanding or filing but don't worry about that you can go back over the edges with super glue and then sand to the final shape. I'll let the laminated parts dry for about 24 hours before working them to shape, this seem to help some.
You could still jump into this build with a smaller project. Thats why I'm building a Tholian web spinner. Its small and has simple lines and should be easy to wrap up by Dec. There are some realy cool shuttles. And if you need some help along the way my door is open. In fact I'm certain most of the members on this build would be glad to offer suggestions. If not I look forward to working with you on the next GB.
Matt