Expanding foam for the foils arrived today, hopefully going to run a few sample / test pieces on saturday aswell as a test blank to make sure the mould will fill without any air bubbles or atleast if air bubbles form we can see what to expect. I'll update with photos after the weekend.
If anyone is interested here is the data sheet for the AMPREG F230 expanding epoxy foam:
http://www.gurit.com/core/core_picker/download.asp?documenttable=libraryfiles&id=1546