This was a days work cutting the CS spar foam. I’m using H35 Divinycell instead of urethane for the 1″ pieces.

I was very particular getting the 1″ pieces the correct width, length can be adjusted later as I may need some mitered edges. The 1/4″ foam I’ve really just roughed out and will get it exact in the jig. Seems an easier way.

Cutting the big sheets

Getting the edges square

Roughed out and ready