Hey Lee, thanks man.
Zee made the usual breakfast and invited "friends" but not one showed up.
Thanks Frankie and Bill.
Bill, I use a fairly high density Polystyrene for the base so it retains its rigidity.
Same for the ribs. 15 to 20mm thick.
I use a box cutter to cut the shapes after I've marked them.
Wire cutters don't work for me.
The skin or surface is 10mm low density sheet that is bonded over the ribs and the high spots are sanded flat with a palm sander (150 grit disc).
For the sharp radii I'll bond short sections and keep them down with masking tape until cured, then do some more. This foam is pliable to a degree but brittle so if you ask it to do too much it breaks.
Simply put, it's like skinning an air frame but instead of rivets and Alclad we use foam and glue.
Next task is to blow mould the canopy windshield. I definitely don't want a 2D shape there.