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Dope
Definitely agree with the aircraft dope idea. Either apply it directly to the cardboard, or add a layer of brown paper (either as one big sheet or cut into 6' strips etc) which may disguise any writing.
Brown paper over polystyrene foam is also good (using water based glue 50:50 with water), finished with dope and then painted works well (or leave naturale), and is nice and water proof. just be sure that the dope isnt applied too thick or it will seep through the brown paper and dissolve the foam.
When i get to it, my front air dam will be made this way..... theres always plenty of packing foam to be had. keep your eyes peeled for EPP foam (model aircraft industry term), which basically springs back when you push on it. very handy for those light impact areas (ie lowest to the ground). i've seen it used for packing office supplies.
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