Now that the layers of foam are joined by epoxy (and cured), it is time to work on proper shaping.
The model has a lot of square corners that require shaping.
The extra foam will need to be removed to create the shape.
A Sawzall equipped with a long wood blade has worked good at trimming the larger sections of foam. The battery-powered sawzall is handy to allow work without dragging a power cord.
The finer work is handled with a smaller grinder. This right-angle die grinder is equipped with a 3-inch disk and works well for some of the more detailed areas.A lot of measurement and effort allows for a foam model that is properly shaped, and looks realistic.
The next step is to create a tough and durable fiberglass shell.