Hey, hows your build going? I am doing something similar - or will be when time and money allow. I've used Riley's urethane foam and standard polyester fibreglass layup technique a few times on smaller parts. You can sometimes get offcuts and failed pours from insulation manufacturers for cheaper foam. You can also use cheaper polystyrene - which is the most common form of insulation in New Zealand where I live. It's readily available secondhand too - from dismantled cool stores. It doesn't sand as smoothly as Polyurethane and the styrene in standard fibreglass will instantly dissolve it. You can use a more expensive resin (Epoxy - about twice the price) in your first layer that doesn't react with polystyrene to seal it off and then use cheap standard Polyester resin.
Hope this helps - would love to hear more about your build
Ross in NZ
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