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if you aren't worried about not making a killing doing this, and just want it as a challenging project, then here are some of my suggestions:
I would suggest using chavant modeling clay instead of foam. Why? Besides the fact of it being some what expensive, but re-usable - you can really fine tune your shapes and forms based on the clays temperature while hand forming or carving or sculpting the clay. I'm not saying to build the whole form out of clay, but just the outer surface, the inner surface can be a wood skeleton. Then make your initial molds from this, then perfect the first castings and make your master molds from that.
If you have tons of money, then i'd opt to get your clay forms 3d scanned and have a cad guru 'perfect' your scans to be ready for 3d printing and molding.
But if you cant do any of the above, then yeah- knock yourself out and get some foam and start cutting and sanding away.
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