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The relative 3D positioning in the foam core is very close to the original 3D model. The CNC machine was usually accurate within 1/16th of an inch, though some pieces were off by as much as a 1/2". But the variations are almost completely "averaged out". The overall length of the foam core "grew" a little in length because I had measured the thickness of the nominal 2" foam at about 1 15/16ths of an inch, while the 1" foam actually was about an inch thick - and there is twice as many glue joints, too. A longer car is actually a good thing.
You can kinda' see my edge shaping tool in the first three photos, by the way - it's the one on the left.
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