Hi m8
While I know MDF has health issues with the dust, youÂ’re going to be hard pushed to beat it for price and ease of usability. I made some display bits a few months ago, and used studding for the frame, then covered in MDF, (you got flat sheet for flat stuff or that pre halfway cut through stuff for curves. The two types cover most uses,) then when done applied a bit of texture and turned it into stone, and painted. Average joe on the street canÂ’t tell the difference unless they tap it. Just remember to either roller or spray paint it, and seal and sand it first before applying the final colour. If youÂ’re in the UK, IÂ’ve found the stuff B&Q sell has a shiny finish so cuts down on sanding between coats, and wickes for the studding for structural stuff, which again is dirty cheap.
You could use that upvc expanded foam sheet, but itÂ’s a pain to join, or you could use plywood, but again a huge amount of extra work getting the surface smooth. MDF cuts easily, sticks together great, and is very cheap.
Not a huge amount of help on the alternative material, but I think MDF is probably the best. Invest in a decent mask with proper filters, not those daft papery things that really donÂ’t do a awful lot, and start sawing.
Look forwars to seeing pictures.
Don