Yeah we think alike....I've already made the cardboard mockup, just not sure how to make it solid. One suggestion was spray it with truck bed liner? Couldn't find any examples of that on YouTube yet, but I haven't done my usual effort of research...just scanned the topic. I'm trying to stay away from fiberglass as I don't have the expertise nor the materials and sanding fiberglass I hear is a pain in the butt, and very time consuming. Trying to find something easier to sand...like the balsa foam idea above...but the expense of balsa foam is what's making me look for alternative solutions...I don't mind work....but sanding aggravates some injuries I'm nursing.
Anybody know much about expanding foam, the Part A mixed with Part B types? I'm thinking maybe I could make my own foam, carve that, seal it with something, cover it with leather, and attach with industrial strength velcro on the bottom where the velcro would never be seen.
Or can the cardboard mockup just be covered in duraglass? (not sure how hard duraglass is to sand, but I know fabricators really like that stuff online) But....I don't want this thing hard and heavy and able to crack my head in case it came loose in an accident. So the form is my number one consideration....but again...balsa foam is very expensive.
All ideas and help welcome...and I like the idea of making a mold....but I don't have the supplies for all that yet...researching it though...as then I'd be able to make more later in case mine got damaged, or possibly sell them...driving around with my cardboard mockup really does add a nice touch to the driving view...more of a race car cockpit feel, very classy.