I want to make a mould for a clear headlamp cover on a sports car.
The body is unpainted (right now) frp, If I could fill the 'socket"
in the front of the car with an expanding foam and work it into shape
after it hardens then I could get a positive, and then vacuum-mould a
bit of acrylic or polycarb to match. The fellow doing the body-work
and painting would like it very much if this did not ruin his nice
work. If there is not a non-sticky foam then what should I use as a
release agent - could be something as simple as parchment papaer I
suppose...

Is there a foam that would suit?

Any other suggestions welcome.

No, these covers are not otherwise available.