I would cast it before I hollow it out. Off the top of my head (no pun intended), I'm not sure how to caste a part that is "hollow" per se.
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When do you think it will be done? Will it be a fan fic character, or a redo of an existing character? Have you already decided on who it will be?
Maybe it could be a "travel trooper" - a clone/stormtrooper w/ a tourist camera and a suitcase?