Over the years I've messed around with different designs on the FX, (along with Wave Hog, aka Carl and SpecialFX, aka JD). After all that, there isn't one "perfect" design or shape. We ride mostly creeks and some surf up here in NJ. The big tubbies help keep the nose from pearling while riding surf (added area), While when long down the side help when riding fast and carving turns. It's all freestyle design for your riding style. The current "tubbies" on my ski are set about 1" from the bottom edge. It forms like another chine when you are carving a turn, Kinda like the old 550's feel when turning/carving. On the other hand JD's and Carl's tubbies start at and close to the bottom edge, and are rounded up from there. Basically there's no right or wrong way for design.
I've ground them off and started over at least twice. I always used 4-5oz.
divinycell foam. That stuff sands so nice as compared to the pink or blue construction insulation. I make tape patterns and mirror them for the other side. It's easier to laminate multiple layers of say 1/4" thru 1/2" to get things to conform and stay on track. Shaping a single 2" thick piece of foam might sound easy, but it's not. Unless you are a master sculptor...lol.
I have some tape patterns (see pix below) that I've used in the past (bottom two blue patterns were from a earlier design that got ground off) and for the current sponsons. The long one at the top was the base layer of 1/4" foam. Then the following layers are 1/2". The final thickness ends up about the width of the top rail. I "glued" them on with U-Pol fantastic body filler. That stuff is hard to find now but came in a toothpaste like bag. REAL easy to sand. After you laminate the foam layers on, you sand to shape, then seal things up with some layers of fine 6oz cloth. I use epoxy resin, but polyester works a little quicker for the cure times. Hope this answered some of your questions...