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Zenair CH601HD

Ahh I did think about making sections, and although it's fairly symmetrical to the eye I'm sure it's not perfect. If I were to do it with pourable foam I would have at least made some kind of cardboard sections/dams to keep it under control, using the spray foam wasn't difficult to build up, aside from the bottom, pesky gravity.

I'll look into the bendable foam, I was thinking of building some 'walls' on the inside of the mold, just wasn't sure what to use to form it, the foam sounds like it might be the trick I need.
I don't think it needs a massive amount of re-enforcement, but I think it should be stiffer, around the split, maybe one or two walls/bendy foam strips on the big spans. I obviously don't want to add a whole pile of weight so I will add a few re-enforcements and see, add more as I feel necessary.

As for the side work on home builds, I don't think I would make a cowl for someone, but I wouldn't mind getting into some of the welding, I've seen some of the welding out there on home builds and I see room there
 
We used ‘polyurethane foam insulation’ on some applications to muffle noise.
Probably would not stand up to hot areas in the engine compartment, but, the foam has good structural properties for stiffening purposes.
One neighbour has used it to reinforce his GLIDER segments.
 
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