i like the papermache idea sounds easy to work with and cheap.

: Making molds its fairly easy, you can use specialized materials, like for
: example alginates, or use what the hardware stores offer (silicones, foams
: etc)
: The materials you will use for mold determine the procedure, release
: techniques included.
: To go very simple and very cheap you can use expanding insulation foam, the
: one in the can, it doesnt stick to the kind of plastic shopping and
: garbage bags are made of, those can be a little tricky to mold so that
: they follow the curvature of the cockpit but if you have some practice
: with that kind of things its not difficult. Using release agents like
: various kind of wax, silicon spray (ive used even the non stick cooking
: spray for some things and worked pretty well) can be a way too. Checking
: on a small spot would be best since different brands of foam can act
: slightly differently. In short you prepare the cockpit, make a
: "lid" for it with cardboard or better a transparent plastic
: sheet held with tape and inject the foam (depending on the size you will
: have to make more than one hole in the lid to inject the foam from but
: remind that you need one hole free for air to exit the cavity you created
: until the end).
: The foam "plug" at this point wont last forever, its good for a
: couple of copies or so.
: A way a little more professional is to prepare the surface with the release
: agent, spray or brush on some latex for molds, found in any arts and craft
: store, if the release agent gets solid, i.e. wax, you can brush the latex
: on otherwise spray it.
: Latex will need a number of coats to be thick enough. Once cured you can peel
: it off so you are sure it releases correctly and replace it in the
: cockpit.
: Again using some foam (you can embed in the foam some wooden strips to help
: with this) will keep the latex rigid so its not deformed while you handle
: it. This one is more durable and several copies can be made from it.

: The method that i consider best for simplicity result and money though is the
: paper marche', takes a little time for the whole to dry and be handled but
: thats the only negative in it. Just wax very well the cockpit, take some
: newspapers and cut them in strips, soak in water some strips for the first
: layer and cover the whole cockpit with them being careful that they follow
: all the contours, when soaked they conform very well.
: Since newspaper ink tends to transfer, thats one of the reasons the wax coat
: on the cockpit is there, you can start your first layer with white paper,
: or even kleenexes (if you use kleenexes or similar stuff its better to
: place them dry and soak them on the spot with a spray bottle, be careful
: to not create creases)
: In the meantime you will have a good bunch of strips of newspaper soaking in
: a mix of water and glue, carpenter glue or white glue work great and if
: you feel like you got the hand for it adding some polifilla or plaster
: powder to the water give wonderful results.
: Start your second layer with those strips and layer after layer you will have
: a plug ready to be extracted once dry, i suggest at least 15 layers with
: wood strips embedded to keep the whole rigid.
: Once the paper plug is separated from the cockpit and eventual creases or
: imperfection are filled, a few coats of varnish (or epoxy even better)
: will give a very durable plug. Again you can spray some foam inside it to
: keep it rigid and for a level, stable block.

: In any mold you will find very useful to embed some tubes for compressed air
: to help release from the original and after from the copies (the
: compressed air gets in between the mold and the copy or original forcing
: its way around and pulling them apart)

: There are tons of other ways to make a plug, some complicated, others
: expensive and others more or less distructive but the two above have been
: used many times with excellent results.

: For molds etc you can check theatrical forums, static modelmaking forums and
: look for moldmaking techniques for other instructions and professional
: forums on the net. Its not excluded that you will find some videos too,
: that is best since all that stuff its more difficult to explain than
: actually do.

: If you need more clarification just ask.