Wow, it's been forever since I posted...feels like coming home!  I have to build some oversize appliances:  vintage refrigerator, front-load washing machine,  and maybe a car trunk (ok that last one isn't an appliance, but I still have to build it!).  If you haven't guessed, we are doing CATS and the director wants what she wants.  Any ideas?  The doors will have to open (the trunk lid will have to raise).  I'm just not sure how to go about creating the look of the outside of the pieces.  Curves...so difficult.  I look forward to your help!

Unfortunately we cannot do any fiberglass casting.  I like the foot locker idea. I am trying to stay away from curves as much as possible in the primary set pieces: we have ruled out the car trunk (so sad) and changed the refrigerator to a more modern, boxy style.  But I'd still like to figure out some way to create more rounded shapes for future reference.

I made a wood car for grease w/a curved trunk

Why not use an old fridge with the compresor & refridge gubbins stripped out.

Thanks for the ideas.  It seems that carving foam is going to be our best bet.  I have pared down the the curves in the set and gone for more modern appliance looks just to make my life easier.  (I hate to make artistic decisions based on that, but I'm a bit overwhelmed with 54 kids in the cast of a K-12 grade production of CATS, and very little set crew).  We open in 2.5 weeks and the costume unitards are back ordered.  Something had to give...and it is the antique refrigerator and the washing machine with a round window!  But the show must, can and will go on...and it will be fantastic!  I just may be ready for a lobotomy by the time it rolls around!