Try small things first, blowing pu foam on cardboard sounds easy and is easy. Cutting it roughly into shape is easy too... It's the symmetrical part that's the hardest part.
And ofcourse most types of foam will not hold up once they get in contact with solvents or heat. So remember, if the foam holds up initially it's no insurance that the heat that builds up while curing will not harm it.
I've tried it, but it's easier and a LOT cheaper to just buy originals or replica's. Unless ofcourse your trying to go for a complete new look.
Have you got any experience with FG or bodyshaping at all ?