I have a 3 axis CNC machine and I am drafting the 1 15/16" thick sections to cut them out of foam. I have done some trial cuts on the foam -- see this page:
http://ecomodder.com/forum/showthrea...-11969-30.html
It has been slow progress, partly due to the fact that I was back at work (for pay) for about 8 months, and also I had to work out the kinks with software and the g-code and the foam and the CNC machine.
I'll post progress on that thread, soon. I'll be making an order for about 100 sheets of foam, but I am doing the CAD drafting laying out the sheets to get an accurate count.