I found the expanding foam had continued to cure and harden. To remove it, my friends Dan and Rob helped me cut it out using a combination of saws-all, pry bars, and scrappers. It was quite a chore but the saws-all made a nice, positive impact.
We found the foam had bonded and hardened against the nose cowl so now I'm rethinking this whole mold process. At the moment, my plan is to finish removing all the remaining foam, then decide how best to proceed using more expanding foam albeit in a smaller amount, or some other way of supporting the opening while I fabricate the opening lips.
