Its about 2m long but working at 500x scale at the moment. I have used round corner but as there are complex contours it has left me hours of cleaning up overhangs.
It shouldn’t take hours to clean up. Soften the edges so you can select surfaces and delete them. That would speed things up. Welding edges will also help.
I’d be more inclined to make a wireframe and use Fredo’s Curviloft or Tig’s Extrusion Tools to skin it. Or going a step further Thomthom’s Vertex Tools and SuBD.
Here is a very simplistic version of what I mean using Curviloft. I have thrown the wireframe together just using the two point arc tool with no attempt at accuracy.
Thats great, many thanks I will look into some of these. I cant go too mad as i am building to a plan. this is going to be 3d printed, carbon glass skinned and will fly.