The dowel I used is an old dry one that I've had for quite some time. That's why I wondered about balsa wood when you first posted.

It is probably light enough for stable flight as is, though probably cannot be reused. Back in the day, I used to use foam earplugs as stabilizers for darts made of coat hangers. As far as reuseability, cloth is a definite no-go.

Shotgun wads depend on how close I am to the target. Too close, and they smash flat.

You're right, an assembly line would make things a lot easier, I bet you can come up with a way to do it. I used a cheap plastic mitre box and fine toothed hacksaw to cut mine at 90 degrees. If you have a drill press and center finder, the rest should come easy.