We started with a big platform, 2x12 frame and plywood, covered by medium density fiberboard.. Then Adam started building a rough shape out of wood. The voids were filled with whatever he could shove into them and then two part expanding foam was poured into and over, wherever it was needed.
This was our first attempt at a complete car's bodywork, we'd done smaller projects, but the scale of this one didn't at first really hit us. Adam has been mostly responsible for the bodywork, he has done the carving, shaping, bondo-ing, sanding, cussing, crying, ignoring it for weeks on end,,, pretty much all of it. Kevin has helped along the way, but Adam gets kudos on this part.