This is the second of my Star Trek scratchbuilds designed by Maseo Okazaki of The Starfleet Museum website. It is made of RENfoam and took a little over two weeks from start to finish. Photo 3 shows the initial foam pieces cut from paper planform and side templates.  The fighter was shaped with a pneumatic sander and hand sanding with 80, 120 and 220 grit sandpaper.
Photos 4 and 5 show it contoured and glued together with CA.  Brass tube was used for the exhaust nozzles and guns.  Fins were pinned on the fuselage.

Photos 1, 2, 7 and 8 show the final shots of the finished model. I used Tamiya paints for the ship and Photon torpedo ( turned aluminum with brass fins ). My good friend Steve Simmons scanned, altered and laser printed the decals for me, and did a great job to add the finishing touch to the Penguin. 

Photo 2

Photo 6 shows the model primed and panel marked, as well as  the cabin windows carved out.  I used laquer primer to seal the foam as well as being a basecoat for the final colors.  The rock cliffs behind the Penguin is a solid chunk of carved Renfoam.   I used 1/8" dia. brass tubes to suspend the ship and torpedo to simulate flight. 

Dan