/cgl/ - Cosplay & EGL

>After some careful measuring, we carved a busk out of styrofoam, coated it with Bondo, then vacuum-formed the outer shell. We reinforced the shell by slushing around a bit of quick-curing resin. [For the screen in front], we laser cut a frame out of MDF.

84% of that makes sense, but how in the hell did they carve this busk out of styrofoam? Do people secretly work with head-sized blocks of styrofoam from the dark web, or am I missing something? Also, there's a bottom half not seen in this pic.

I've tried using EVA foam but it feels like it's gonna be too thick to fit in all the parts + my head. Naturally, I'd rather not go through the rest of the steps if I'm right about that.
(Pic and quote obviously aren't mine. They're the goal I'm trying to solve.)