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> The design aspect I'm fine with, and I'm sure I could find a creative solution for creating a 2D cross-section and polurethane
> foam plug, but I wanted to find out if there is a better way to go about it? I realise MDF etc. are good options for flat areas,
> but are there any other good methods for building something like this?
Will you have to build a windscreen, too?
In general, when you want to build round, symmetrical objects which have compound curves (curved in more than one direction) you are actually entering boatbuilding and aircraft/automobile design territory. The still most important tool in those trades is called a batten, a thin, long, perfectly straight piece of wood which can be bent. This allows to produce visually pleasing, continuous lines by aligning it with existing surfaces, and checking for positions where material is missing or needs to be removed.
Position the car perfectly level, or establish a level plane like the edge of the cockpit. Determine the middle of the car with a piece of string weighted on the ends and a plumb bob. This establishes your absolute zero, "waterline" and stations from which all measurements are taken. Build a platform made from plywood or similar material approximately on the lower height of the planned roof. On this platform you will build the roof structure.
Get many thin long strips of wood and start building the general outline of your roof. The battens can be bent to produce compound curvatures. Generously overlap the battens onto existing car structures for continuous lines. Take measurements from the middle line, stations and height above the platform to ascertain the structure you are building is absolutely symmetric. Support the battens with lots of pieces of wood or even properly shaped thin plywood glued into place. This is the actual design process, but you are also building the plug. When you're finished building a lattice structure of your roof you can fill the empty space between and under the battens and support structure with foam and then pour a layer of 2 component pour foam on top. This is then sanded into the desired shape.
I don't have pictures showing this process and I'm lacking the proper vocabulary in English, but I hope this description made sense.
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