Welcome to the forums! Have you checked the latch side of the frame for plumb. Place a level on the face of your molding. I believe you will find the hinge side to be plumb, but the latch side to be out about a half a bubble. Your old door may have conformed to the frame from the date of manufacture, but the new slabs, although they are flat, won't fit a warped jamb.
I'm not familiar with that foam but I would try a handsaw. It should be long enough to bridge across the hole. Flex it and push it flat against the door surface and tape some cardboard to protect the paint from scratches.
Great - thanks guys! I'll report back on how effective the saw is!
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