I think I'm now on the 4th iteration of a quadcopter with a plywood body (the first had plywood arms too).
I was motivated by the need to provide an alternative for the FPV drone market that wanted something different, and perhaps wanted to try out different things with their drone - a good internal volume is handy for mounting components and things like single board computers or cameras.
I was also motivated to actually make something. I had spent a lot of time designing drones and took a year to make a prototype (although by no means full time) of an inspection drone, that flew OK but required another go-around the design loop.
I wanted to make and fly more of my own work, and using a simple, and modifiable architecture just makes all of that easier.
So, here we are, at the fourth iteration. I had made 5 of the previous version and I had found that if you weren't careful, you could easily end up with a twisted frame, because of the clearances and the interlocking structures (especially the motor beam reinforcing assemblies. I realised that by making the top cover plate non-interlocking, and moving to removable arm assemblies (which I felt were needed anyway) The main 'pod' could be made in two steps. This also provides the builder with better access to install components before securing the top plate. The assembly can be made without twist, especially with a little weight added whilst drying.
There's never a free lunch though (more's the pity...) the downside to all of this is that I need to use more captive nuts, and unfortunately I also needed to move away from the very light panel nuts to the larger M3 T-Nuts which are much more readily available. There is a middle ground that can be used if the parts can be found.
Additionally, you just end up using more fasteners if more parts bolt on, or you have more access hatches. I think I also have a fairly nice solution to this problem - automotive trim rivets. I have found a small one that requires a 5mm hole. I shall use these for most non-structural joints, with just 1 or 2 screw in fasteners.
OK, that's it for now... I will tick the 'email followers' button as that gives you all feedback that your donations didn't just go on beer, but if you don't want to receive updates, I am sure there is an option to unsubscribe.