Hytec, Here are the tools I use the most for carving foam in place: a Sharksaw dovetail saw and a curved Surform rasp. The Sharksaw has a flexible blade and it cuts like a hot knife through butter. Yes, I did see your edit. Surely other readers may be curious too. Thanks for asking.
I was always one of those believers that foam needs plaster over it. Every layout I've seen without the plaster has very obvious seams. You seem to have covered them well.
Have seen a very large layout that used the sand over foam technique. Owner says it gets very heavy as he uses many layers to shape his slopes. I've dabbled with masonite, but have had encouraging results using styrofoam (thin of cousre) carved to serve as bridge abutments.
I think I found my first choice for a host in a DIY Model Railroading Show: Todd! Great job! The pictures and the explanations made it seem like I was sitting there watching you while you did this. Awesome work and great detail! Keep the tutorials coming! Maybe you should record these and put them on YouTube! :thumbs_up::thumbs_up::thumbs_up::thumbs_up:
Todd, thanks for showing your tools. I'd never heard of a Dovetail saw, gonna look for one. How do you control the foam litter from sawing and rasping? A weak vacuum cleaner comes to mind, but I'd be worried about sucking up the finished scenery nearby.
Hank, I keep a small shop vac in the railroad room all the time. I sucked up foam debris 4 or 5 times during the process to keep it under control. I think the vacuum cleaner is as important as my Exacto knife. It's especially good for cleaning Bright Boy track cleaner crumbs from turnouts.