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Unusual neck construction help

Also, if I understood and remember correctly, Heiko (Basslab) uses a foam core (for the whole instrument) then dissolves out the foam.

That's what I recall as well. Ulrich Teuffel was doing something similar with a guitar body, but he developed an allergy to some of the chemicals involved and had to discontinue the model.
Also, Pete Swanson (Dagmar Custom Guitars) uses a CNC-carved foam mold as a scaffolding to build his 'houndstooth' guitar bodies, then carves/melts out the foam afterwards.
It's a viable approach, but it sounds pretty messy!