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Hi Rob,
Nice and interesting project you're doing there!
About the styrofoam and fiberglass problems. One thing you can do is to cover the styrofoam with self adjesive aluminum tape. This tape is typically used on home and commercial ductwork, a little heaver than your typical aluminum "foil". Just cover the form you want to fiberglass with it, effectively sealing the foam. I believe you can also wax the tape, allowig the 'glass to be removed once cured.
Another option is to use polyurethane foam - pretty sure it's the stuff they make surfboards from and I don't belive it is attacked by typical resins used in fiberglass work (polyester, vinylester or epoxy). They've been fiberglassing over foams for decades, key is using the right kind of foam.
Jeff
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