Hey Everyone,
Thanks for the measurements and the suggestions.
Let me explain more clearly what I am going to attempt. Basically I am going to take the measurements and sculpt a form to the appropriate dimensions, sort of like an old fashioned patternmaker. I will then make a mold of the form. Now, depending on the complexity of the final form the mold may be a simple two-part mold or a multi part assembly. The parts of the mold really only facilitate removal of the final product. After I have a suitable mold I will then use mix and pour liquid foam to cast a pad from the mold. Varying the proportions and the venting of the mold will determine the density of the foam, i.e. the more venting = bigger bubbles (gas has more room to expand) = less dense foam or vice versa. As a side note the foam that I am considering can be pigmented (meaning colors other than black).
I'm sure someone will question why I think I can do this. Well if you look at my profile you will see that I'm an Art Conservator. This means I have a BA in the classical studio arts, and an MS is art conservation/ preservation ( I specialize in 3D objects). Included in that MS, is experience in replicating missing parts and making damage disappear. My MS research was in plastics (i.e. polymer materials). If you ever visit a museum and think that everything is in perfect condition as it appears, think again. There was probably someone in my profession that had a hand in making it look presentable if, of course, that's what is necessary.
Thanks again to everyone for the info.
Namastay,
Cheeba-Fi
P.s. M Rael I may try contacting you via email outside of the forums at some point.