team design
Cran,
Wow! It does sound like you have thought alot about the ways in which a new helicopter design could be born.
My thoughts are: (hope Dave doesn't mind this use of his thread)
I would like to help get a safe design(s) built for the same motivation that someone would work on a cure for polio. Not out for money, would be OK to earn some money, but more interested in the science and adventure. Designing, building and testing a new helicopter may be beyond the capability of one person.
For a group effort, the plan you have suggested of a kit built machine makes sense. Or maybe just a set a plans and instructions could be provided to the group members and each could build or buy parts from vendors (other group members with special skills). A non profit association of helicopter builders may have less liability if each member is considered to be the manufacturer for the helicopter that he or she builds. You cannot sue yourself if you are the manufacturer.
The problem is how can something be designed by a committee and still be light enough to fly? I'll be thinking about that.
regards,
slowrotor