Very nice work on the DV's cowl. Yeah, blue construction foam is great for fine sanding and using as a mold. I just use 5 min. epoxy coating on the outside applied with my finger that hardens the mold enough to vac form over it.
Oh, yeah I was in my glory untill the Boss, Ann came down and gave me grief as it was after 10:00 and I had the sound of to guns going (You know unlimited ammo)