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.

square corners-1

The extra foam will need to be removed to create the shape.big cuts-2

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.

big cuts 3

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.fine sand 4A lot of measurement and effort allows for a foam model that is properly shaped, and looks realistic.

rounded 5

The next step is to create a tough and durable fiberglass shell.