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You might have to apply the foam in two or maybe even three thinner layers so it sets up without sagging and falling out like you have shown in your picture. When I did mine it set just fine, but it wasn't any thicker than 1-1.5" thick and that 1.5" was between the slats of the grill. Also, there is nothing stopping you from still using what you have there. Make sure its cured, maybe shape it a little, and you can always add more foam on top of it. It'll stick together.
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