FLD (15/06/2014)
Thanks Warren. That was my original thought I just thought I'd ask to see if there was a lighter option.
If time is not an issue you can actually form closed cell foam into some fairly complex shapes with careful use of a heat gun and neat cutting and trimming. trim it roughly to size, heat it, clamp into position and leave to cool. The foam will then hold that shape. You then have to make up individual pieces and mark them so you can reposition them during lay up, a bit like a jigsaw puzzle. Very time consuming but actually quite satisfying as you end up with a very strong yet extremely light panel.
Warren