Tried out foam for the first time on some freezing block for an old GE monitor top refrigerator. Turned out better than expected. Some porosity which I'm assuming is pouring too hot but otherwise I'm happy. Thank you Kelly for all the posted guidance. Foam blanks ready for casting. I experimented with a laser etched logo on hardboard dipped in acetone and then pushed into the foam. It worked ok given the method. Laser cut profiles for the foam cutter. I used the instructions at: http://www.rcsoaring.com/rcsd/RCSD-2008-11.pdf to build my hot wire cutter (page 101).