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RE: A commissioned sculpture for the town of Colonial Beach Virginia (USA).
Interesting details and work processes.
Yes, weight can be a problem, so your solution works good. When I worked on stage designs eons ago, we used industrial insulation spray foam for some stuff. On something precise as this, it would not wok that good, but we made supports with wood and rebar, covered with cloth etc and sprayed it - some surreal stuff was to pull pantyhose over a wood support and spray-fill it; controlling it before it sets by had and tying.
Working from the inside out: makes me think of seeing that with Gustav Klimt on an unfinished painting - apparently he painted (some of) his (female) subjects in the nude and only dressed them later.
That's interesting what you say about Klimt and makes sense when you think about his paintings. Actually, in the past, we did use spray foam of a particularly solid variety. We got it from Dow chemical; how healthy was that? Our sculptures started out looking like swamp monsters.
haha, funny - but I think that may have been the same product we used. Where it worked really good was to build the Badger cave for "Wind in the Willows" - a segment of that tale, "Toad of Toad Hall" was our annual Christmas show at the UofL Drama Dept. - I have not checked lately, but I still got credit years later on the show posters for stage design (I also painted Toad's ancestor portraits).