Hi
thanks for the feedback. I've only built one Warhound (who needs more than one?!?) as I was challenged to do so by my son. As mentioned at the foot of the post, I quickly moved on to build a Stompa afterwards which was much simpler. I'll put a post up about that shortly.
The Warhound start-finish time was 3 months based on about 2 hours work, three times per week. I got distracted into other tasks whilst doing it though: the Titan when built needed to be fielded and for that I needed an opposing army. We decided to play Imperial troops (my Imperial Guard and a friend's Marines) against an allied force of Orks (I had a bucket full of bits which I had to quickly assemble, including scratchbuilding a Trukk, a battlewagon and the aforementioned Stompa and then basecoat) and Necrons - that was the "other scratchbuild project" mentioned in the Titan blog: for another christmas present I scratchbuilt a Necron monolith for another friend.
Like I said in my blog, there are a lot of problems with those plans so take care to reinforce everything. I think my biggest problem though was the cardstock used - plasticard when scored and folded tends to break along the fold. Card-card tends - as you've noticed - to not give a hard edge, and is also prone to tearing. For the most part I stuck with plasticard and ran a bead of hot-glue along the inside of the fold, but I have to say that got very, very difficult and messy in places and I wasn't happy with the technique.
I'd be very interested to hear what you come up with to solve the problem. *Then* I might build another one