Well took apart the router again last night to fix the exhaust fan and found that the JB weld quick set was all flimsy!! Mixed another small batch of regular JB weld and so far after curing it feels much stronger. So hopefully that will finally be over.

Going to goto Lowes and check to see what other types of foam they carry to try and cut. Hopefully one that is not nearly as soft as the pink insulation foam sheets.