I'm sure this question has been answered before. However, I've scoured the threads and can't seem to find it.
I will begin construction on a 5x8 foam trailer shortly. I know my way around a shop, but this will be my first trailer build. I plan to use the 2" Foamular 250 panels for the walls and roof. I have never worked with this material before, so I don't know the best way to approach it.
I plan on inserting 1"x2"s into grooves cut into the foam. They will provide support and as studs to drill into. What is the best/easiest way to cut 2" wide grooves into the foam? I've kind of talked myself out of using a heat knife, because it's a new method and it doesn't look super foolproof or accurate. I just know I'm the kind of guy that would either burn himself or make awful messy cuts. But I'm open to suggestions. I would prefer to use a router, but how does the foam hold up to routing with regular woodworking bits? I know it's got to make a mess (foam-dust everywhere), but do regular router bits make clean cuts? If so, I'm eyeing a pretty sexy 2" wide surface planing bit. I think the bit is 1/2" deep, so two or three deepening passes ought to get it to the right thickness. However, the bit is around $50 delivered, so if it's not going to work I'd rather save the cash and look at other methods.
I'm leaning on y'all for your hard-earned experience. You're awesome!
Ben