Carl,

I'm re-thinking the pylon skins to eliminate having to burn anything, plywood or paper. Since they're just skins, they could be simply cardstock, or something just slightly thicker. I'm going to try some simple posterboard (WalMart grade) for the first prototype.

Attached below is a revised set of balsa cutting patterns, using the information you gave. I'm setting the tiny hold-together tabs at a nominal width of 0.03". See if this comes closer to your laser's needs.