[aardvarcus]

Freebeard,
Thanks for the tip. I have been sanding the shredded surface with an orbital sander as a work around, I don’t really do much foam shaping in the grand scheme of things or I would be more motivated to make/buy additional tools.

Everyone,
Speaking of foam shaping, I got a few of my pieces roughed out of foam last night. I am trying to get the foam blank closer to the final shape to reduce the amount of shaping I have to do, which is taking much longer than expected versus making a large oversized block.

Edit: I forgot to add I got two tanks in for a preliminary baseline (with tire swap and trim removal) showing 23.6 MPG for short trips and 25.6 MPG mostly highway.