I have done this carving either free hand with a series of knives, or with those same knives and a set of metal rulers, T-squares etc...
On the advice/recommendation of Jeremy from Black Magic Craft on YouTube, I broke down and bought a Proxxon Thermocut hot wire table. The Amazon Prime fairies delivered it yesterday (one day shipping to have it for some of the weekend), and I got to play around with it a little bit last night.
|Proxxon Thermocut Hot Wire Table|
Oh my gosh. Why did I wait so long to get this!?!?
The wire heats pretty much instantly after hitting the ON switch, and can cut 2 inch thick foam sheets with ease. There is an adjustable fence that can be used on two sides, and can be adjusted for any angle 0 degrees to 90 degrees. It's like a mini table saw for foam.
I have yet to spend much time doing anything with it other than the briefest of test drives, but in a matter of maybe 5 minutes last night I was able to rip several 2 inch tall strips of half-inch foam using the fence, and then freehand those strips into a number of pieces that will become ruined walls.
|Ruined wall pieces - mere minutes to make!|
Amazingly quick. And easy. And uniform.
|Pieces would be assembled like this...|
Good stuff. More to come...