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?

Cardboard then CAD I would say.

CAD and Lazer Cutting seems a little OTT. Hand cutting/shaping should be more than adequate. Trust your eye. 

Thanks all.

Interesting point of view Warren. Do you think it's possible to match both sides? When it's painted any kind of flaw would surely be highly visible?

Are you concerned about the profile/shape being identical? or the surface finish? 

Both really.

I think I'll do that - templates to get the dimensions right then foam and just keep measuring. If I can't get it accurate enough I'll have to get it digitized. It's the curved element I'm concerned about.

Even if you get the foam profiled on a CNC (not cheap) you will still have to seal the surface and add some sort of reinforcement before you can take a mould from it. So there will still be a lot of hand finishing to do. I think you will be surprised how accurate you can the shape by hand. It should be possible to match the left/right profiles to within a millimeter or so.

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.

Don't really see and advantage in that method. You are just increasing the time/cost/work involved. Make a Mould- Make a part from that Mould- Re-Model that part- Make a Mould of that modified part - Make the part from that Mould !!!!!!!!!! Why ?

Carbon Copies Ltd

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