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Old 06-27-2011, 11:16 PM   #28 (permalink)
skyking
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Go back and read what I posted. figure out the stations and cut those out of plywood with a sabre saw. Mount them on a "keel" of wood to keep things straight. Trim and adjust those so they will form the outline you seek.
Cut cardboard to make your "slice" templates. Once you get that cardboard to butt together and not overlap, you have a useful set of templates to transfer to plywood. For a "one-off" like you are building, I don't think it warrants making a whole set of 3D CAD drawings and slices.
Do one half to the exact midline with the cardboard. Now you can use those cardboard templates to make both the left and right sides.
You can make the stations out of thicker cheap plywood, thick enough that you could screw your slices to them while working it out. You can stitch to those, and then use the sawzall to trim it to 2". At 2" it is still a useful frame for strength but adds little weight.
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2007 Dodge Ram 3500 SRW 4x4 with 6MT
2003 TDI Beetle
2002 TDI Beetle

currently parked - 1996 Dodge 2500 Cummins Turbodiesel
Custom cab, auto, 3.55 gears
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