Here's my DIY velomobile. Everything except bicycle specific components like gear shifter, shocks and chain are made using Aspire and my CNC router. It's going to replace my car for local trips and commuting in harsh weather. I use a regular bike when the weather is nice. Aspire has taken over almost all of my CAD work because it's so easy to use.
Windows are 1,8mm acrylic. The shell is made from pine plywood. The thickness varies from 3-18mm thick depending on how it's pocketed and doubled up. My Photobucket account has more pictures from the whole process.
It's really heavy. At least 65 kg, but the assist takes care of that. It has a 250 W nominal pedal assist motor (Bafang) so uphill travel is fast enough. It's pretty comfortable, with suspensoin on all wheels, and has room for a lot of stuff. The goal was to replace my car. I want t omake a new velomobile that's lighter, smaller and faster for fun.