Foam in a can is 3-4 dollars around here I think. As I mentioned I used a great stuff gun, it gives much better control and is reusable unlike a normal can of great stuff. I have a picture of it below.
As you can see, you just tuck the aluminum in as best you can around corners and tape it down on the edges.
This is the great stuff gun (pro 14). Its great.
Tonight I sanded down the grill block. It went pretty quick. The only difficulty comes from the fact that the foam is a bit spongy. If you aren't a little careful you can end up ripping it instead of sanding it.
Removed the grill block and trimmed the edges.
As you can see, the surface is far from perfect. I'm going to put some fiberglass over the front face to reinforce it. We'll see what its like after the fiberglass goes on.