[Stevebsy]

Originally Posted by SilverSpear

This is alll the wrong way to do a custom fabbed car. Either you should have the machinery and equipment to fold metal sheets the way you like and start the welding process, or you should use CLAY for a preliminary shape then take from it the "lightweight" parts through a mold.

Actually the processes both of the above used are standard industry practices. The foam is cut, shaped, and then bondoed up and primered over to create the pattern. Then molds are made, and the pieces you see in the finished pictures are fiberglass parts from the molds, not the whole bondoed/foamed thing.

If you have $$, the foam can be cut by a giant CNC machine, but not often is that the case for most in the one-off custom car type world.

There are some other ones out there too. This one has an excellent step by step explanation & pictures:
http://www.desicodesign.com/meerkat/Bodywork%201.htm