[NeilBlanchard]

I glued another 8" today -- the rear door opening has been started, and the is only another 3" to go, and then the bumper and the overhang of the hatch door.

I'm going to repair the Phlatprinter 3's X-axis belt and buy another sheet of foam (it's less than $12) and cut another copy of the sheet. To many hassles to try and do all that hand cutting.

Only the portions that have a lot of taper have very much foam to remove. Most of the car have just ~1/8" to come off -- the random orbital sander with 50 grit or 80 grit pads with make fast work of that; and it has its own dust bag or you can use a shop vacuum attached to it to collect most of the dust. The pads have 8 holes that suck the dust right from the surface, and it works pretty well, really.