Surfboard - BoardCAD Thruster

This is a full scale surfboard model, broken into 53 pieces and arranged on 14 plates for printing.

The board design is the default thruster shape from the open source, GPL'd surfboard design software BoardCAD:
http://boardcad.com/

I started to print the first plate in ABS, but canceled it half way through because it was warping and cracking.

I'm posting this to get some help with experiments with different materials and slicing settings. I'd like to see a pretty thin surface and minimal internal structure - as minimal as it can be to hold the shape when assembled and put up on the glassing stands.

If you get all the parts from plate 1 printed nicely and fitted and glued together, let us know how you did it. Thanks!

By the way, we don't imagine that 3D printing is a practical or efficient way to produce surfboards. My interest here is to explore efficient internal structures for surfboards. I'd like to see a cell/network type structure like bone, with varying density. There's no "bone" infill choice yet in slicing software yet that I know of, but I'm sure there will be soon. Maybe you can figure a way to approximate that by hacking current options. At the very least, it would just be nice to be able to print these large parts accurately enough, without warp and cracks, to be able to assemble them and glass it. (If you and your bot village are able to print it, I'll be glad to assemble and glass it.)