This is Part 2 of my experiment with a ton of canceled gas station gift cards a friend gave me a while back.
The thin laminated gift cards are 54mm wide by 86mm long. Here are the designs I drew up for a small shuttle or escape pod on index cards, for those who may want to re-create the experiment.
Here is my sketch for the top:

Here's the bottom:

After cutting out the cards according to the drawings above, I went ahead and folded (dashed lines on the drawing) or, in some areas, just bent (dotted lines on the drawing) the cards in the following manner (top portion of the shuttle is on the right, the bottom on the left, seen from different angles):




After sliding the top half into the side "grooves" of the bottom half, I went ahead and glued the sides first (seen here from various angles):



After the glue on the sides is set, glue down the flap in the back first, followed by the one in the front. The result make the nose look a bit deformed at this point, as can be seen here from several angles:



To remedy that initial downward-beak-like distortion, use a pen to gently curve the top of the cockpit section:

So here ya go, the basic hull shape, as it stands now:



If the shuttle looks a little short for 15mm, just gently squeeze the sides of the hull and adjust to the height you want.
After that, the hull is ready to have styrene plates added to the open sides.
So, what do you guys think of this second attempt at making a shuttle hull with just two thin laminated gas station gift cards, a ruler, scissors, pen and super glue?
Comments and critique appreciated.
Dan
http://www.flickr.com/photos/9593487@N07/sets/72157630977964238/