This spring we're doing Once Upon A Mattress at my high school. I have designed a pretty elaborate headboard in AutoCAD. My question is what should I build it out of? It's 3 feet high and 3 1/2 feet wide and needs to be a few inches thick. I want to keep it light weight and cost effective. Also, as much as I would like to carve it out of hardwood, I don't have a lot around at the moment and I think it will weigh too much. So, I thought about using some kind of two part foam, but the products that I found in a quick Google search didn't turn out very cost effective. Does anybody have any ideas? Thanks.