Made from 1.5" EPS foam (@32 sq ft). Surfaces are 2 layers laminated together using Great Stuff spray foam and low temp hot glue.
Once the general shape is established, I carve away the excess with a wire brush and then sand everything smooth with 60 grit sand paper.
So far this project has cost $22 in foam (direct from the manufacturer)and 3 cans of spray foam (@$24)!
Less than $50!
THAT'S A LOW PRICE!