Headliner Shell Fabrication

The guys who built the buck to make the mold for Chico State's Human Powered Vehicle fairing used styrofoam. They then coated it in latex paint to keep the resin from eating it. Worked well.

I've pondered this project. I think that I'd use non-corrugated cardboard. Cut it to shape and fit, Glue any seams and use tape to hold it while the glue sets. Then paint it with polyester resin after removing any tape. As the resin starts to kick paint on some 2 oz. cloth and continue to laminate until thick enough.