Just a quick question for you guys, What bit are you guys using to cut the foam? I have been using a single flute 1/8" bit but I have been having problems with the foam mealting and sticking to the bit. I have tried from 15-30 ipm and it still happens sometimes. using a 1/4" trim router for the spindle I havent tried slowing it down. I also have a dremel multi speed tool i am thinking about making a mount for and using that as it should have enought power to cut thru the foam.
Darren