I have actually just drawn up plans for a flat sided lure. But it is only 40mm long. Let me know if it is any use to you.
Yes, there are nearly always going to be problems. When making a new bait, you have to assume that it may take a few prototypes to get to what you want. When you build up experience with building a lot of lures, you can cut down this work and occasionally get it right first time. But to get the most out of a particular body shape does take a few trials, lip sizes, tow eye positions, ballast locations.
Dave