by Tom&Shelly » Tue Apr 23, 2019 3:22 pm
When I cut the voids in the walls and bulkheads I didn't bother to necessarily make the cuts all that straight--just what I could do quickly with the jig saw. I rough cut the foam with a utility knife snapping it clean, then put the piece behind the wood and traced the void with a Sharpie. Found I had no trouble following the outside of the Sharpie line with my band saw. Gaps between the wood and foam were usually less than 1/16" or so. (Only reason for the rough cutting was for the pieces that didn't clear the 12" clearance of the band saw.)
The foam dust was pulled down into the saw just like saw dust, but the foam dust charged electrically and stuck nicely to the painted metal sides of the saw until I vacuumed it off. Not much in the air, and little on the floor even. This is in New Mexico with single digit humidity. Your atmospheric conditions may vary!
Tom