hehe, oh man! I just found that foam spackle stuff, I wrote down the info and I think I left the name and online contact addy at the office! grrr, I'll get it to you monday for sure! so sorry *is dumb*
Here is the stuff, it's called ISO Foam, from Foammart.com, it's perfect for a spackle for foam. once dried it can be sanded much like the foam, it's a similar consistency. You can top coat with a fiberglass gel coat or I sometimes paint on a coat of resin
ewww, sorry about that mate, I just pick it up from the foam store down the street (LA is good about having all the effects stuff handy in the Valley If you need any and can't get that wreck of a website working I'd be happy to pick it up and send it to you.
hmm, well, I haven't given it much thought, but I guess I'll mold mine to start, cast them in resin, sculpt to match his photo's (already downloaded several) silicone mold and cast in dental acrylic. Easy as pie