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Old 09-14-2010, 10:13 AM   #115 (permalink)
RobertSmalls
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Join Date: Aug 2008
Location: Buffalo, NY, USA
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Prius C - '12 Toyota Prius C
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You've earlier mentioned that you can't make foam and fiberglass copies, but how about a fiberglass or carbon fiber monocoque copy? The overall shape may have enough curvature to make it strong enough, and internal ribs could be added if needed.

Sure, it would be heavier than your original, but it would have much better craftsmanship than anything I've produced so far.
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