Ron Bell and Grant Sible at Gossamer Gear were nice enough to give me a few hints, like tape and sew each seam if you want it done right. They are great at making this stuff and I'm VERY thankfull that they took the time and effort to help me with some important questions in making my own gear. I'm definitely NOT interested in making this gear as it really is a lot of work and a true craft. Cutting the patterns on the CNC cutting table is something our company could do for a manufacturer looking for precision cut pieces. The rest was just lots of thinking and trial/error and playing around with the cuben. I built a few small test pieces to make sure they would really work before making the final parts. For example: I built a guy line, sandwiched it between some wood 2x4's and pulled to see if I could break it. Not sure how I came up with the corner tieouts but them seem to be really tough and distribute the load well. I kept thinking this was going to weigh more than I had calculated as I kept using more and more tape and grossgrain but somehow it ended up being lighter than expected. I really took my time on this project to make it turn out nice. Just a lot more work than I thought it would be.
I have a long table that I use as my work space. Lay down the first piece of cuben and use masking tape to keep it tight and hold it in position.
I just layed down the 3M tape with a 1/8 margin on the side. Use a roller to set the tape really well to the Cuben. Then, lay the panel you want to attach on top of the panel with the tape.
Use masking tape to position and hold the top piece in place and keep the panel tight, and get the perfect fit up. Then, I start peeling off the tape starting on one end and slowely move along the seem. I hope that makes sense? I should have taken a picture of this.
Do a search on Cuben and you will see a lot of Post from Bill on working with and sewing the cuben. I got all my info from him and Ron Bell. Use long stiches and good thread from Quest. One thing that works well in sewing is using silicone on the needle. The needle will want to gum up going through the tape. I clean the needle with alcohol and then wipe it with silicone every 4 to 5 feet of sewing.