What is the consensus on joining 2" thick foam cutoffs to make larger panels?
My plan is for a 5 x 5 x 10 foamie of approximately this outline:
I will have a lot of cutoffs of significant size. I'm not concerned with joining the pieces to make up the sides as the joints will be under compression, but what about the top? There will be 7 pieces 5' 4" long to make up the top. does anyone see any issues using joined pieces to span the top?
I would use a hot wire jig to cut 1" x 2" grooves in the edges, then use 3/4" x 3 3/4" foam as splines, then use Great Stuff to fill in the gaps and glue them together. Like this:
and this (3/4" x 2 3/4" spline):
I know the main strength of the shell comes from the canvas/tb2, and I won't have a lot of weight on the top, so I think it will be OK.
So what does this community of TTT gurus think?