Buggies

[KDRacing]

Hey everyone,

I know this isn't related to boat building, but hopefully you'll be able to help me anyway. I take part in a race in Pittsburgh that involves racing small monocoque cars, called buggies, down a hill in a way similar to soapbox derby. Weight is a concern, because when you reach the bottom of the hill, you then have to put them back up. I'm making a new buggy this year, out of similar materials used to build boats, and I was wondering if you would be able to help me with a problem...

When finished, the shell for the buggy should be empty and a unibody, which means the plug has to go somewhere. I was thinking dissolvable foam or something, but since I don't have a large-scale CNC router (think college student budget), this is extremely hard to manufacture. Pulling the plug out the front and the bottom of the shell have both proven to be pretty tricky, because reattaching the pieces is very difficult (the way I know how to do it). Is there a pourable, dissolvable foam or wax that would make this job easier? Or a method of plug construction you know of that could help me? Time is also a factor, as I would like this shell to be done in a month or less.

Here is a picture of what the end product generally looks like: http://www.andrew.cmu.edu/user/awg/b...ture%20037.jpg

Thanks!
- Adam