Welp, here it is, the FOAM prototype
The version on the right is the first one. its a dense styrene (packing foam) and i wasnt really happy with the results. It would have taken a lot of time to clean up and make look right before the molding process this weekend so I had him do up a second one in a lighter styrene (the left one)
That one turned out much better and a LOT smoother as you can see. Still needs some cleaning up which i will do with a xacto knife and dremal to define the windows and some details more (like the grill).
After i do that, I will brush over a light/thin coating of drywall mud which will fill all the holes and give it a gentle sand to smooth it out, and again add the finer details and sharpen up the corners where needed.
For those interested: Total Cost, 400 bucks for both "prototypes" as opposed to 1000 for a 3D Print/Rapid Prototype version.
Then its off to the mold making guy who will create a sillicon mold of the smoothed out prototype, and then Ill be able to pour/cast my final "buck" for the thermal former!