I want to design something similar to the below (not to copy it), but I'm unsure of how to go about it.  I'm thinking the high density foam to get the shape of one side and the front, glass it, flat it etc etc before moulding but what about the other side? By hand it's not going to be identical, so what about someone with a digitizing arm to map it then "flip" it, then have it lazer cut in foam? 

Or make up a cardboard mock-up and find someone who can CAD it before lazer cutting foam etc?  Any ideas anyone?  How is this stuff usually done?

Take a mold off original shape,then make Out off fiberglass then reshape or profile to what you want,then take a mold off that and your good to go.

Take your point but that's ripping someone off effectively and it's a massive load more work, as warren says.