Step 3: Ears 2.0 (WIN!)
I was feeling pretty low after the resin debacle. I stood there hanging my head in shame...just staring at my feet. When it hit me! I should really put on some appropriate footwear. Also, the floor mat. I remember watching a Youtube video by XRobots.co.uk about making an IronMan costume where he used foam floor mats.
Using the wooden ear as a template I cut out multiple foam shapes and layered them as I did the wood version. After the layers were bonded I coated the whole thing with wood glue. The wood glue, so I was told, would seal the porous foam, and make a harder shell. It did both. 2 points XRobots.co.uk, 0 points My skepticism.