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The inside radii are proving to be a pain for the shaping and smoothing process. I'm going to need a good oscillating saw very soon for some other other areas.
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Is this the problem you asked about in
#post324285? I looked at oscillating saws in Google images and in addition to jiggler saws and Sawzall, there is a medical style. It looks sort of like a powered putty knife. A knife blade might cut cleaner than a saw blade. I know that's the case with corrugated cardboard.
I had to read Galane's description twice; but I got it, as his render confirmed. What I'm not seeing is why a router drawn along a straight edge wouldn't be quicker. A router is a high-speed tool and should leave an acceptable surface on the foam.
FYI the pictures in
#post336352 no longer load.