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#1
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Razor knife and straightedge oughta be able to make the cuts, just have to figure out how to get consistent depth.
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#2
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This was what I tried first and it was surprising how little it did for the flexibility. The foam wanted to break instead of bend. I think the width of the saw kerf helps give the foam more flexibility, it just means I'll have to fill the gaps. I epoxied three panels last night and they worked well.
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#3
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