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RE: Have you seen GIK's new diffusers?

EPP is Expanded Poly Propolene. It is VERY tough and will not crack like styrofoam or any of the styrene compounds.
Good luck SOURCING EPP, though. NO hobby shop will routinely carry it. They would ReSell far less since it is so darn DURABLE.
EPP is a closed cell foam and will take paint and is immune ot most solvents. I'll HOT GLUE it together when ready. I might not even use a BACKER which is an extra part NOT needed if I'm correct.
I can buy 24" x 48" sheets 2" thick which I can EASILY cut with an electric carving knife. I'm making the cutting jigs right now.

I think many would agree that WOOD is simply too heavy and ends up with both mounting problems and resource use justifications. Though I suspect, for the last, the synthetics are WORSE.

If you don't think EPP is 'special', check out the videos at Crash Test Hobby where a flying wing
is repeatedly flown INTO A BRICK WALL

I think the 1.3# per cubic foot stuff would work fine.
Too much is never enough

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