Steve, how much foam are you talking about?
If you want a lot, go to the source. $400 minimum I heard.
EPE Packaging Inc., Southern California
Orange, CA 92865, USA
Marko Foam in Corona sells EPP with a $100 minimum the last time I talked to them. a 1.3# block 4"x3'x4' was around $30. 1.9# available at additional cost.
Phone: 1-800-8marko1 or 909-272-4700
If that is still more foam than you need, then contact Flyingfoam.com or Daves Aircraft Works. Both can hook you up with smaller quantites.
http://www.jspi.com/ is showing as the best resource from the www standpoint, I'll give them a call and see what they are requiring volume wise to get the costs down, looking at foamfly.com, it's just nowhere near the ballpark to cost effectively build with the stuff at all so would hold off unless money isn't an issue, I'm also comparing it cost wise to eps or the epp arf's and replacement parts currently on the market, will take the 25.00 striker replacement body for example at the lhs, along the eps, the fact you can cheaply replace it without having to pay for shipping since it's off the shelf, cannot see epp taking over what I build with in foam creations until the costs go way down.
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