I know in composite experimental aircraft that hot wire sculpting structural foam is a go to method.
MT's method of sculpting compressible foam is one I would not considered to great a stink Steve points out.
Access to a band saw allows a alternative that I have had much experience with Knife edged band saw blades.
Nice for clean cuts and no shredded material and certainly no fumes. Won't deny the riskiness. Uncoiling a blade was usually accompanied with curled toes. Was the bee's knees on polyethylene foam UPS safe packaging for computer touch screen monitors back in 1997. Opra had one
Tom
MT's method of sculpting compressible foam is one I would not considered to great a stink Steve points out.
Access to a band saw allows a alternative that I have had much experience with Knife edged band saw blades.
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Tom