I have experience in working insulation foam. I layer polyeurothane and plasti-dip on the foam so it makes a durable shell on the foam. So far I've made Paracelsus and ABA's body keys from Guilty Gear, and I'm in process of making Zorin Blitz's Scythe from Hellsing OVA and Twing Twang from Heavenly Sword. I'll be uploading photos of the scythe soon, but Paracelsis is in my gallery. The materials would and labor would cost about $160. Where are you located? I'm in la, and I'm not too sure how this would ship, lol. Let me know if you are interested. Thanks!