Sorry guys, not been too clear.

Ineed to have a full size buck cut out of a foam block from a CAD design. From this buck a mould will be taken to fit it to a chassis.

At the moment I could do with advice regarding what material to use for the buck. Someone has mentioned doing it in foam then some kind of metallic spray over it before taking the mould in GRP.

Hope that makes it a little clearer.

Thanks.