The main hull was made out of pink foam insulation board (Extruded polystyrene). The board
is available at most Do It Yourself (DIY) stores like Lowes and Home Depot. I used the 2" thickness for this project.
You can substitute styro-foam packing material if you don't have access to the harder pink or blue foam.
You will need a hand saw, a large kitchen knife, or a hot wire foam cutter to cut the foam.
Be carefull when using the knife because the foam often slides around if you don't hold it secure.
I based the rough dimensions of the hull off of the old GW templates:|
Hull is 4 1/2" long x 2 3/4" wide. The 2" foam gives you the height. (Just over 2")
Rear bumper area is 1" high.
Both front and rear angles can be cut into the foam as desire. I did mine so the roof is a 2" x 2" square.
Once you get the main hull cut out you can sand the surfaces down with a sanding block or sandpaper laid flat on a table.
Once your happy with your new slaneeshi gobsmasha, OH sorry, it will not be pink very long.
The cardboard plates are next. Lay your hull down on a piece of cardboard and trace around the edges
to mark your cardboard. I used a marker so you can see it better in the pics but use
a pencil so no ink will bleed through and ruin your wagon after you paint it.
You can vary your plates a little. Don't be a weedy 'umie when you place your seams and plates,
get a little Orky. No need to try to be square or plumb, just slap 'em on proper like a true Ork mek boy.
Cut your plates out with some sissors. Then glue them on with Elmers white glue (PVA glue).
Finally, pin the plates down with small wire nails. I use all different sizes but 1/2 " is a good 'un.
The wire nails are available in any DIY store.
After working with dozens of these nails your fingers are gonna hurt so use an old soda cap like
a thimble and push the nails through the cardboard with it.
Once you are plated add a few extra patch plates to indicate repair work etc.