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guess that's why they are called gurus. I would have never thought of using two part foam to make the base mold. I wonder if you could spray the foam in place, sand it to the correct shape, glass...

One of the glass gurus says;

remove the port wing
buff all gel coat around this repair with a non silcone compound
use 2part foam,shape the foam
grind the gelcoat back about 8"
grind glass to...

Any friends with the same model boat you could pull a quick mold off of? That part would be fairly easy if you do.

Hopefully Artie will see this. What kind of access do you have behind the hole?