Well... This project was not abandoned. Just moving slow.
how does this approach sound: shape the foam as close as possible, fill with what, plaster? Car filler? Once filled and smooth I could cover with fiberglass or I could make a female mold and then make a super nice mold... If I make a fiberglass mold, I assume I'll need to reinforce the inside. And then comes the fun of figuring out how to attach it. I was waiting to cross that bridge when I got there.
Thoughts? I'd like it to look nice. I'd also like to figure out a way to have a hatch that opens still too...