Thanks guys! It's a lot of fun and very forgiving, I recommend that everyone try it - you'll really be amazed what you can crank out. All of that was done with the following tools:
Wood saw
2" paint scraper heated with blowtorch
Sureform rasp (an absolute must have when working with foam)
Dremel with drum sanding head and 1/8" spiral cut bit.
120 grit sandpaper
I put some of the primer/glue on a bit thick for a few panels and it was still wet when I started carving. Some started to de-laminate a bit but a squirt of Great Stuff
TM and a few toothpicks locked everything back down.
Also, as a note if anyone is looking to start working with foam, bondo disolves polystyrene. You have to seal the piece before you coat it (and that's only necessary if you have a lot of laminate sheets like I do, or want to change the surface texture). I used the same Glidden Gripper
TM to seal the piece as I did to glue it all together. I used a foam roller and then went in with gloved hands and used my fingers to really work the paint into the cracks so that way when I go to bondo over the whole mess it doesn't shrivel up and disolve away.
If you wanted to make the whole thing hollow you could bondo it all then drill a few holes and pipe in acetone and wash the whole mess out. Also, if you want the styrofoam to be super hard I recommend using half bond and half urethane resin mixed together with bits of fibreglass sheet cut up and mixed into the compound. The bondo activator will work on the resin also - it's called "bondo-glass" and is pretty much the hardiest stuff around, but is total overkill for this application.
Anyway below is a pic of the stand sealed and drying. Tonight I'll be able to apply the bond and start doing some of the bark effects on the build. I'll also start foaming the CP and may start on getting it shapped as well. You can see R2 in the back, the drink tower is back to chrome now (I keep changing things on it trying to get the look just right) and I still need to make the updated drink tray - so busy right now), but he serves beer and should also serve as my jukebox here shortly...or whenever I find time to mess with him lol.
