I doubled the bracing around the top of the shoulder and added additional bracing to create pockets within the leg to fill with spray foam. By feel, the leg has some more weight to it and the foam adds considerable reinforcement to the bracing. Here are some pics:
After letting the foam set for a couple days and noting that the expansion has stopped, I was able to mount the top (outer) panel to the leg and let is sit under weight for several hours until the glue set. I then glued up the first styrene strip around the shoulder. I'll let that set over night and continue tomorrow on some of the other skins. I will need to spot putty this when done to correct some cutting mistakes, but so far, I'm happy with how it turned out.
I assembled my first pic flasher and ran into issues there too. I have proper voltage throughout the pic but I'm only getting output from 4 of the 8 traces. I've only connected a couple LED's and tested with a meter. Not sure if this is at all related to the defective crystal issue that was going on, but I may be calling Carls.