I think you should drop all that stuff an just move towards small cell.This could
save you alot of time and effort.The Bees would be happier also.
Why would the bees bee happier with small cell?----Asking myself
?Smaller cells - Smaller bees---less storage area---smaller bees = less work?
Missed the point. The Hexigon shape of the honey comb cell is one of nature's strongest. The shorter the sides of any multiple-sided object the stronger it is. The bees will make as much comb as it take to produce brood and stores, the size of the comb is really immaterial to that. What is important is that a small cell full of a bee pupae leaves little, if any, room for varroa mites. That's why the varroa prefer drone comb, there's more room that allows them to reproduce better. Also, small cell in Apis C., from where varroa came, is smaller still, which is why the varroa is almost exclusively lilmited to the drone comb in Apis C. In Apis M., being a larger bee the mite can more easliy fit into worker sized brood cells and therefore the varroa mite population multiplies much faster. Man, in his wisdon, has created wax foundation that is larger even than what Apis M. manufactures on their own, thereby compounding the problem.
Smaller cell size is only one of the answers in a multiple answer solution to a particular problem, but, IMO, a valid one.