Shaping Blank

This is ny home made belt sanding table.
I take off the excess foam with a rasp file first and finish with the beltsander. I jsut sand down to the epoxy edge. It´s so hard it´s easy to use it as a guide.
Here is the foam blank with correct outline, sanded to epoxy edge.
I have marked a guide line on the top of the blank and am sanding down the blank to the epoxy edge. Go slowly and gradually, use long strokes to avoid uneven sanding.

Finishing the edge

This is the underside of the movable slider used to hold the electric router.
I adjust the router depth and route off the excess epoxy to make it flush with foam.
I sand the edge lightly with a rotation-vibration sander and with a sanding block.

Here i am cutting off the excess foam.