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DIY R2D2 projector Answered

Hi All,

So I had this idea of putting a pico projector into an R2D2 body so I can recreate the Princess Leia Hologram moment. I wanted to get some suggestions on what sort of materials I should use to build the body of the R2D2 droid.

I see some people mold using styrafoam and I was thinking of going that direction but would it be better to use something sturdier just to house the projector? I also want something that would look cool but I dont have a 3d printer or any experience using plastic molds. 

The projector is an AAXA p4 pico projector:
Dimensions: 141*71*31 mm 
Weight: 0.4 lbs

Anything tips to keep in mind before I start construction?