For making plugs with anything soft like balsa, drywall mud is your friend. Sands like balsa so you don't over-sand.
Might have been able to do this whole thing on the printer but likely just as quick and accurate doing it by hand, some printed parts and some hand formed. Fairly square and symmetrical but as you can image the center line of the nose isn't perfectly centered so playing the compromise game to get it better.
First pass at primer and blocking to confirm shape works. Will crisp up the lines and flatness, then a mold.
Beginning shaping the sides. Guys in the shop are a ton of help, with helpful eyes! Super thankful. Lots more before a mold.
I'm pretty sure this is ride height, at least for the street. 4 1/8" in the front, what do you think.