My friend Dan built a dam and tapped off areas as needed in preparation for a new attempt with the expanding foam. This time we opted to only pour the foam around one of the inlet openings.
After mixing up what I thought would be an appropriate amount, I poured it into the nose bowl and let it expand. It only took a few minutes to realize once again I had mixed up too much foam. I really only needed the foam to rise slightly beyond the flange of the inlet air opening. As you can tell from the photos, it expanded a bit higher than was necessary.
However, after extracting the mold, I was very happy as I can work with this. There is a small air pocket along one edge that I will fill with foam prior to shaping for the new opening.
