The hallway rings each have 19 small pads. For each ring, there is one pad directly overhead, with 9 pads down each side of the inside of the ring. Our current 3D models show 24 rings, so that means 456 of these pads will need to be fabricated.
Then there are the much larger hallway wall pads, and the smaller corner and gunner tube pads.
I’ve been using expanding urethane foam from smooth-on for my Wookiee underskulls. It captures excellent detail and is pretty strong and light. Once my current Wookiee projects are done (spring or summer 2013) I can jump on these.
From the looks of it, the ring pads will need 3 different masters: 1 for the small pads, one for the medium sized pads in between the two small rings, and a third long bad for the longer sections of the tubing.
Straight pads on the cockpit and gunwell cooridors.