I'm loving your content, I'm interested in developing an ultralight myself. I want to replace a wood and fabric wing design with aluminum and fabric. Have you read "Sheet Metal Building Basics" from the EAA store? If not you should, lots of great information well presented. In this video you mentioned using 1/8" rivets through 0.016" skin. This is too large a rivet for the skin thickness. Chapter 19.4 states that the rivet diameter to thickness ratio should be no greater than 5.5, otherwise the expanding rivet will locally distort and buckle the sheet. For 0.016" sheet the largest diameter rivet that can be used is 1/16". See Table 2 on page 19-4. I have not been able to find 1/16" pull rivets so it will be necessary to use solid rivets. One other comment. A downside of starting with a large sheet, bending it, and cutting out lightening holes is that it results in the most scrap so it adds considerable cost (the need to buy more raw material for the same end result). While I agree that the 5 piece nose requires making more parts and using more rivets to assemble them, the parts start as straight rectangles that then get bent into shape so there is much less scrap from the raw materials. If solid rivets are used they are cheaper, lighter, and stronger than pulled rivets, but they do require different tools and learning the techniques to install them. If your ultralight is going to be primarily aluminum then the one time cost of the tools will be small compared to the number of rivet you will need to set so using solid rivets where ever possible will ultimately cost less, be stronger, and weigh less.