Yeah, the lighting stuff is sufficiently complicated that I've never wanted to take the time to master it. And I'm sure that's somehow the root of the problem.
The nose cone will be turned on a lathe, either from a cone to start with or, more likely, from a block of balsa. I think. It might be feasible and less expensive to make it out of three off the shelf pieces, a cone and two transitions, just as it's built in RS. I'll have to do some investigating.
And it sounds like we're agreed on upsizing the fins. That'll let me core out the nose and reduce the weight, so it may well result in a performance improvement.