You too? I had been doing good this summer since my meds were stabilized, but my headaches are starting to come back. Not as bad as you are talking about thankfully, but it's still pretty bad. It keeps me from sleeping and makes it hard to concentrate more than anything else.
I ordered some vinyl to fix my dashboard and I went through the process of removing the cracked plastic to expose the foam padding like everyone did on the Camaro forums.... except my foam is so rotten it turns to dust in my hand..... so now I've got to figure out how to build it back up so the vinyl has something to lay on. Tried memory foam... too soft. I'm on to cardboard now and it isn't looking great.
Thankfully my usual headaches have always been manageable.. plus I just got used to them enough to just ignore the little ones. The bigger ones usually just mean some ibuprofen and maybe going somewhere cool and dark for a while. Unfortunately my back has kept me from getting more than a few good nights sleep in the past year. Last night I think I woke up at least 20 times, probably more, to change positions. If I take some ibuprofen I can go the first few hours without waking up, but after that I make it maybe 20 minutes before I have to move again. Sometimes I take Nyquil just to sleep through the night, but I pay for it the next day. By the end of a day at work sitting at a desk, I can only go 2-3 hours in front of the computer at home, so my writing has suffered too. Sitting down on the couch doesn't help much, but then standing and moving doesn't either, lol. So I just live with it. Gonna try doing the medial branch block with nerve ablation on the left side at the end of this month. Had the right done but it only lasted about 2 weeks (not the 6-18 months it's supposed to last). This stuff is all a crap shoot anyway. I'm actually hoping the prednisone I am on will alleviate some pain and allow me a couple good nights of rest before getting worse again. Oh well, if I'm lucky I'll get to deal with this for forty more years, lol. At least I can type again without too much pain.
Wow, I guess I did have a little more anti-chuff in me

Oh, and on the foam, If you want it somewhat soft try the high density stuff upholsterers use to shape lumbars and bolsters in seats. you can shape it with electric knives, files, rasps, and even sanding blocks. If you just want it barely spongy maybe do spray foam and then shape it after it is completely hardened. The stuff in the can might be too porous to get a good wrap on it though. When I used to make panels for car audio, we'd use anything from wood covered in straight vinyl, wood with 1/4 or 1/2" high density foam over it then wrapped in vinyl, spray foam trimmed down and wrapped, wood skeletons wrapped in stretch cloth (speaker grill cloth, fleece, or even jersey fabric) and fiberglass resined then filled with bondo, or even just wood with angelhair bondo filler to shape it before wrapping it in vinyl. I think those old dash panels were injected high density foam that was put in a mold then wrapped in vinyl, but the foam they used is higher density than the stuff they sell in the can at the hardware store. Still, that stuff does work and if you get any big voids you can always touch it up with more foam, it's just messy and takes overnight to harden up. You can always get some quarter inch high density foam at a fabric store and wrap it before the vinyl to cover up the smaller air pockets and still get a smooth wrap with the vinyl... Any way you do it you have to have some decent sculpting skills to get it to look uniform.