It was our plan to outsource the plug creation to a company with a large format 5-axis CNC machine and save us weeks of time in building it from scratch using the tried and true wood and 2-part foam....not going to happen as the work would cost over $15,000 and we would have to wait around 30 days as they were very busy. Plan B....and actually Dustin's plan was Plan A material. The idea was to break the car in the computer into 158 or so 1" thick "slices". Those slices could then be cut by a large waterjet out of 1" foam and all the shapes assembled into a full size model of the car.
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