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Once the foam expands but before it sets up, can you screed it like concrete, cake icing, or spackle compound? If so, you could use a lot less of the stuff, with less sculpting needed.
Also, since foam insulation board comes in urethane with foil backing (R Max?), perhaps a basic plug in the right shape could be inserted into the bumper gap, then sanded or sculpted. R Max is fairly fine consistency, with smaller bubbles than expanded Great Stuff, so sands and sculpts well. Gorilla Glue is essentially the same stuff (just not foamed), so makes good adhesive.
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