To make the 1/10 scale model, I added slots to each form to accept each perpendicular form, scaled them down to 10% of full scale, and I laser cut the forms out of 3mm basswood.
This is similar to wooden boat "lofting" drawings - sections through the shape at spaced intervals.
Do you feel like you get any minor errors in tracing a line with a poly line? Just curious how much you have to blow it up to avoid errors.
This guy in Seattle, Adam Nonis, is a complete wizard at fabricating / molding / vac forming / shaping / altering / sewing / painting..... It's amazing. He built a cool Volvo 122 shell on top of a running BMW E30 chassis...just for fun.