Excellent topic. If you guys do proceed, I wish you success. Git It Wright made some very important points. Unless you have access to large quantities of good balsa, you may want to limit your efforts to making plans and instructions, instead of full blown kits.
I don't know if this will help or not, but I'll share our experiences, mostly from the point of view of a prospective customer.
First year experience was 4 years ago. My oldest son built the two planes from the Freedom Flights kit for B division (2005). The planes flew well. Covering with tissue was an adventure, but we learned a lot.
2nd year was BLG with my youngest. He was in 6th grade. We got the Freedom Flights glider kits. Building was an adventure, especially the wing tip lamination (yogurt lids worked best). One good glider was completed, another was a crazy thing that flew decent, but not consistent. Before regionals, we needed a better glider, so I just drew up wing plans to the specs, but with angled tips instead of the circular ones. The difference was wings were easier to make than FF wings. The kid did a nice job, and the glider actually flew a bit longer than the FF glider, despite being 2.8 grams.
3rd year, we just started with what we had the year before, then with the wing span increase, just drew up new plans. We tried fuse changes to try the needle nose thing. Worked well. By this time, all wings and stabs were just drawn up and built, using the specs from the rules. I know some teams went high tech with 2 at States using wing tip dihedral and tip fences. Our much simpler glider with full wing dihedral (much easier to construct for MS kids) lucked out and won due to supreme guts in launching technique. At a higher site, maybe not.
This year, the kid had a few things going for him. An older brother who had done WS for 4 years, and building experience. All he did was look at his brother's plane, and made a motor stick as close as he could. Second plane had a little stiffer truss on the motor stick, but both were light (<3.5 gr.). Wings started with last years glider design, then he wanted 13 cm cord (13 is his "lucky #) and built wings similar to glider wings, but bigger in size. Planes all now use built in motor stick/tail boom angle and post/socket on wing and stab. Worked well enough. He can now cover with mylar much better than I can.
I guess the bottom line is, all of these designs worked well with good construction. All of the ones we came up with are relatively easy to build. Any team with a coach/mentor that has some experience can do this, though most teams that I see continue to buy kits of some kind. So I guess I see your idea being targeted at the teams without mentoring. You would provide the mentoring, design, and maybe some components, provided that you can put them in your package and not charge too much more than they would cost elsewhere. One thing that remains is, how do you get in contact with those teams so they know about your services?
