I have made three (one failed, we'll call that one practice) nose cones using thr blue foam method. I think it was 1/2 foam stacked to make a 5" dia x 12" ogive(ish) tall NC and a 3" dia x 15" conical NC. I glued my stack together with elmers wood glue thats what I had lying around. Covered both nose cones with a couple layers of fiberglass. I am also lucky to have a lathe at home to do this work on. And I second krusty's comment, it does take time but to see the finished product is awesome.
When covering the nose cone in fiberglass use a glass that is fairly flexible so it will fit around the curvature of the nose cone. On my first failed attempt I tried using 6oz glass. It was rather difficult to get the glass to fit the nose cone. On my successful nose cones I have used a lighter, I think 1.5oz fiberglass. It needed a couple more layers but the result was much better.
I attached a picture of my ogive nose cone and my method of spinning the nose cones. Glassing the tip of the conical NC was a pain but I managed to get it. Disregard the black lines its just marker lines from when I traced the stencil onto the glass. Good luck have fun!
L1: LOC Phantom NERRF 5 H125
L2: 3" Scratch Built Neon Dart LDRS 31 J285
"The man who follows the crowd will usually go no further than the crowd. The man who walks alone is likely to find himself in places no one has ever been before." ~Albert Einstein