I think the Open Hurricane Project sounds awesome, let me see if I can change it to that.
It would be ambitious work for somebody out there! It could be possible. You could derive 1/5 scale parts in a similar manner to gedburke3‘s methodology, starting with some off-the-shelf kit and scaling up the parts accordingly (without treading on toes of course). You could 3D print these parts, and something like a more detailed cockpit interior and exterior parts. You could then ‘skin’ the framework using more traditional methods, trusting that everything is compatible with your 3D printer’s substrate.
Alternately you could re-scale the parts from the balsa kit and have them laser-cut by a commercial company. How you scan each piece I do not know, nor do I know what format (etc) you would need to provide the company with.
To keep costs down, there may well be companies in China that could do either the 3D printing and laser cutting for a cut down cost if you are buying multiples. I’ve liaised with a few musicians I know in a particular circle, and we’ve discussed having an unusual bass guitar design built in China with, say, five of us involved to keep the costs down.
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