thanks again. i don't own a router so i'm not going to go with the rectangular chinook insert but with the 1" round one instead and drill 2 holes in it. and put 2 maybe 3 layers of glass over it. that ought to do the trick, right?
as far as cure rates go, given all the options, could you suggest an optimum rate in order to avoid melting the foam?
i'd read elsewhere that one way to go about it is to use a 20 minute epoxy but let it go off for a while before drooling it into the hole, thereby reducing some of the heat. i also read that it's extremely important to keep the hole as snug as possible so that the resin doesn't pool and overheat anywhere.