RE: engineering project help
Well hopefully that motor has enough power.
Blue Styrofoam can be bought at home improvement stores. They have some 2" stuff that would work well. Since this is for speed I would still go that route and I would use pine dowel rods to reinforce/hold it together. Using spray glue (appropriate) to bond the foam. If you get enough info build/use a hot wire method to speed up the process.