(Edited to add in what I left out this morning)
Introduced myself back in August last year in this thread.
intro-and-few-questions-t893.html As you can see my design has evolved a tiny bit since my speculation in that thread.
Outside dimensions are 30 1/4" tall, 17 1/4" wide, 8 1/8" deep and all the plastic has UV stabilizers added. Exactly what and how much I don't know... Pretty sure the pigments them selves add to UV resistance to varying degrees. Intended wall thickness is 3/16 but will be thicker in corners and slightly thinner in flat areas.
The indention in the back is a 22 1/2 degree french cleat for hanging the house. Another of the many things I need to test in the next few weeks. If it does not latch as well as I hope it will be changed to a 45 degree. Made it at the shallower angle because I was worried about it being difficult to de-mold the part. See now there is no problem in that area and wish I had made it steeper.
And gosh <drags toe in dirt> my first sales inquiry
Like you I don't want to push any limits, so will await Joe's clarification on this.
Have several ideas about how to market my houses including offering just the shells with instructions on various baffles. Obviously BCI certification is a very important first step. As I mentioned in my email to you earlier the shells unlike completed houses can be offered wholesale to other builders. Looks like I will need an in between price.
And I already have two ideas for all plastic baffles. One involving roto molding and sand... The other is trying to duplicate expanded metal as expanded plastic. Google "expanded metal" and think 'expanded plastic'.
http://www.youtube.com/watch?v=wt2MY2LpkuEAnd if you or some one beats me too it... Oh, well Ideas are cheap. I have thousands more
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William
But you could knock em out in a hurry. Probably have cycle times under one minute! 
