I Cheat!! :tb-tongue: We have a foam manf plant in nearby Opa-Locka. They make the sheets 6ft x 12ft and I have them cut it up to 2ft x 6ft where I can manage these smaller sheets on my band saw. You should see their saw! I usually buy 10 full sheets at a time. They stack 5 together and rip the six footer to 2ft widths. Afterwards, they cross-cut the lot in half. Usually takes them 3 min to do the whole job.
The straightest cuts I've gotten have been on a 10" table saw with a standard "rip" (maybe 30 tooth) blade. It did make a lot of foam dust and you can't pause or it'll melt the foam. Unfortunately, my Dad needed his table saw back, so I've been struggling to make good straight cuts. Scoring then breaking always seems to give me an unwanted angle. The best method I've come up with is to use a 2 1/2" hobby blade (heavily waxed) and run it along a straight edge multiple times until I've completely cut through the foam.
10" table saw with a standard blade put it in backwards, CUTS like a dream no melting or such. ohhh also hook up the shop vac to saw =) cw
Hmmmmm...years ago I used the reversed blade trick for cutting siding. I may have to give it a try on some scrap, for future reference. Unfortunately, for my remaining cuts that will almost all be curves, neither my table saw nor my circular saw would be of much use.
