I have used a couple of pints of the TAP foam. It is great for making shapes and excellent at gluing pink or blue board together.
Another way of doing what you are doing is to make v shaped strips of pink or blue board and tacking it on the inside of the your panel. I would make the outside from a layer of fiberglass on the outside and a layer of carbon inside it. The fiberglass will leave a smooth surface and the carbon stiffness. Then add the strips of foam reinforcement making triangles and an other layer of composite covering the foam in strips. Balsa wood can be used in place of foam.
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