I was wondering if you had considered this type of plane layout?



since you know the spacing, you could put a temporary grid on the plexy then use MoI to cut your curves down the middle and place each side seperatly. It didnt sound like you were going to automate the task of drilling?

There would be a couple smaller inner horizontal planes to accomodate the upper and lower pieces but seems like it would work. Trying to visualize though.