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There is considerable overlap between good vinylester and cheap epoxy. If you really want tough, consider System Three Phase II (no financial interest here, etc. ) but before you are done sanding, I'm sure you'll consider finishing off with an easier-sanding substance. If you want good properties, seriously consider vacuum-bagging. It would help get the labour down with epoxy. WEST also has GLR resin to save layup labour, and it can be heat-cured in the sun for improved properties. . . .
For a big boost in crash safety, add layers of cloth and goo to your foam blanks, and finish the inside as well. And really taper out the material from the hard points.
I'd definitely make it as small and tapered as possible, as suggested above.
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