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One thing I will add, Joost. Is that if you do decide to go down the Truescale DX path is that you would likely need to take deposits. I've seen many times on here that triggers the idiots. If you take people's money they, both rightly and wrongly, start making demands. I think one of the reasons you've not had much trouble, apart from obviously being an honest and nice guy, is because you show the items almost completed first and keep the time from paying to receiving down to a minimum. I know you've taken money up front for the Throne Room and Corridor, but I think that higher cost items and any delays may cause you hassle.
Existing customers who have your work and understand your process will also trust you. Noobs may be less tolerant.
Perhaps, like the Throne room, you could show a good idea of what you're about to produce first. Or, produce the Detolf-sized version first, having ironed out production kinks, and then take payments and deposits for Truescale on the understanding that little will change - just dimensions like the service corridor.
Great post, A1.
I think the process you suggest makes quite a bit of sense, and the concerns you raise are also valid.
Since it was Joost's large scale DeathStar Dio that kicked off all of this excitement and established his reputation with all of us, I'm hopeful that Joost is willing to at least consider a test run to see if a limited production of TrueScales could work, or if it reveals the downside you are highlighting above.
For me, the Tantive Entry Way, and a few others on a short list possibilities would be nothing short of Grail pieces. So if there's a descent chance this could work without causing undo hardship for Joost, I'd be all in...