Hi,
I hav a tried and tested method. I recently gave a clinic on it at the 14 South African National Model Railroad Convention. It is extremely strong, very light, and easily shaped.
I have a presentation I can email if you want.
Briefly, I build up the strcture with foam board, we call polysturene locally. I then cover the form with paper towels, which are coated in a diluted mix of white glue (wood glue) and water. Depending on the weather, it is generally diluted at 80% water and 20% glue. You can also add colouring to stain the structure. It dries solid and strong within 24 hours.
I tried to add some pictures to show you, but this did not work.
You can contact me on ralphdav@tiscali,co.za if you would like a copy of the presentation.
Regards
SPrulz