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Thanks for all the responses!
Daox: I was digging through my pile of scrap materials, and there was a small piece of yellow foil board, like what you are in using. I said to myself "Ah ha! I bet that's urethane in there!"
NeilBlanchard: I did some searching on a prop-building forum and saw a demo of using PVA glue (plain white school glue basically...) as a coating over foam for building Iron Man armor. It looked REALLY good.
I'm planning on doing a test with white glue over foam and see how it works.
I DID do a test with aluminum foil, and it worked well for preventing damage to the foam, but as was said, it doesn't bond to the foam at all then. Would work fine for mold-making!
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