After cutting out the structure from 30 thou styrene and lots (I thought) of bracing, the walls were covered with PVA followed by a couple of millimeters of DAS, smoothed with a wallpaper seam roller. None of this is new of course. I copied all of the techniques from Iain Robinson's blog which is full of superb examples. Have a look here at the latest.
The drying process overnight showed up some inadequacies in the bracing with a few warped walls. However, they can be bent back into shape and braced after the event and any cracks filled with DAS.
Then comes the scribing which leaves a sore forefinger but is actually quite relaxing when accompanied by Radio 4 (or Radio 4 Extra when the alternative is Front Row with Mark Lawson).
What about windows? Off the shelf, bespoke, home made? On Mikkel's blog I read a discussion on the Silhouette Cameo cutter. I couldn't resist buying the smaller version - the Portrait - and what a wonderful toy! Reasonably priced too considering the cost of bespoke windows. With forgiving and easy to use design software included it was no trouble to produce a few sample window built up in layers - window frame, top sash and bottom sash for example. I couldn't get it to cut through 15 thou styrene but the sheet was sufficiently deeply scored to make cutting through by hand with a scalpel a very simple task.
I just wonder how durable it will be and how often the blade will need replacing but so far so good. It goes without saying that I am looking for more excuses to play with it.