FYI, part 2 is up:
Building an Ultra Light-Weight Car, Part 2
It talks about shaping the body with "Adfoam ‘M’ grade modelling type expanded polystyrene blocks"
Wish I knew how to get me some of that stuff. Maybe I should talk to the engineering dep't at my old university. They're not too far away.
I have to admit I was a little disappointed that they subcontracted out the finishing steps, after the shape was glassed (sent it to a bodyshop for fairing the imperfections and paint). Getting an "automotive" grade finish may be the single most time-consuming part of doing work like this.
Building an Ultra Light-Weight Car, Part 2