I should have been more clear. Too much catalyst dissipates with an acrid, almost vomit type odor, often accompanied by a pinkish color shift and/or haze. This is a different smell than the normal outgassing of formaldehyde. In my opinion, companies that use a diluted catalyst are just trying to sell more product. A gallon of catalyst at 3% lasts a lot longer than a gallon at 10%. 3% ratios are not difficult to measure with reasonable accuracy.
Crew weight. There is a wide range of crew weights that is competitive in the Viper 640. The average of all crew weights at the 2015 North Americans: 550 lbs. Crew weights ranged from a low of 490 (#10) to a high of 650 lbs.
A Heavy Spacecraft weighs between 15 and 50 tons, and requires between five and twenty crewmen. A spacecraft is incapable of interstellar travel. A spaceship is typically larger than a spacecraft, typically above 40 tons in weight. A Light Spaceship weighs between 40 and 100 tons and requires ten to thirty crewman. A Medium Spaceship weighs between 100 and 1000 tons and requires twenty to five-hundred crewmen. A Heavy Spaceship weighs more than 1000 tons and requires over five-hundred crewmen to operate. A Spaceship is incapable of interstellar travel.