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Stop Using Ferric Chloride Etchant! (A Better Etching Solution.)
Mix 1/2 teaspoon of baking soda into 1/4 cup of distilled water. Brush or spray on. The baking soda neutralizes the acid which is there to slow the curing process.
Homemade Roller Bender
You can get plans for the John Smith busker organs here:http://www.johnsmithbusker.co.uk/He's pretty much the guy who started the modern homemade busker organ craze.
I thought the center of gravity was a bit high, but that was a great effort on your part. I would suggest you looking into the books by Percy W. Blandford who was British canoe designer who designed similar, but successful skeletonized boats covered with painted canvas. My Favorite one is titled: "Canoes and Canoeing" by Percy Blandford. It has several good designs of lite and inexpensive boats.http://www.amazon.com/exec/obidos/ASIN/B004TNZ50Y/ref=nosim/addallbooksearch