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Yep, that's one way of doing it.
I have made an airbox in a similar way before using acetone to dissolve a styrofoam core. I covered the foam in parcel tape to stop the resin dissolving the foam during layup, then peeled what was left of that out of the part.
Happy to help with CAD and design, know a few places that will CNC foam too
Ok, bit beyond my pay-grade from a technical stand point here, how does this sound as a process:
?