On Sat, 2 Jan 2010 15:46:30 -0500, "Don Phillipson"
wrote:

"Nate Nagel" wrote in message
...

1) It appears that in an effort to make a tight fit, I cut the foam
board just a little big. Is there an easy way to shave it down a
little? It doesn't "shave" well with a knife. Am thinking Surform
file? Or will that just make a mess?

When this material was new, the favourite tool to cut
it was an electric carving knife. The edges will always
crumble, but the elec. carving knife can be held more
steady than other tool, which reduces crumbling.

See: "Sculpting with the Hot Wire Sculpting Tool" for foam.

http://www.youtube.com/watch?v=Pn9Jp9Bu-lA

An industrial type would be needed for cutting flexible urethane
molding.