Here is a snowmobile cutter I built over the last winter. It is a cat chasing a mouse chasing a chunk of cheese. The cheese is the hitch and the cat is the actual trailer. It is sized to carry a banana box and a bit more. The cat's tail is a handle to open the storage area and is held closed with magnetic latches.
As I haven't made anything with foam and fiberglass in some time I wanted a project with many compound curves.
People ask if it will carry passengers. I briefly considered a rumble seat but despite our well maintained roads it seems passengers deserve a suspension. Someone without a snowmobile might consider a smaller dog or person pulled version or toboggan.
Step 1: The Planning and Layout
I started with a general sketch of the cat. The mouse and cheese were ideas that came later and were not originally planned.
The sketches were then turned into various scaled drawings with the layers of foam inserted within. The approximate shape of each layer was freehanded over the various surfaces but a lot of time was not spent trying to match coordinates between views. It was easier to tweak the layers as they were cut and shaped.
The measurements from the drawings were scaled up and drawn onto pink extruded polystyrene foam insulation. I started with a simpler sub assembly, the skis, rather than the main torso. The parts were cut out and glued together to create the appropriate thickness. Each section was then sculpted and shaped. This step was accomplished using a mix of hot wire cutting, saws and sanding.
As the legs were fairly simple, I started with them.