While we're on the topic of foam, I just wanted to say that I use the white stuff for my tombstones and I've had no problems with it at all. The reason I bring it up is that you may be able to find pieces of the white stuff for cheap or free. I get my foam for free from a company that takes giant foam billet and cut styrofoam inserts to install behind vinyl siding. They typically have 1”-3” pieces left over that are about 3' square. I found this place by looking for foam manufacturers in my area yellow pages and then made a couple of phone calls. You guys should definitely try that; it could save you a ton.
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