Rather than destroying a saw blade or 3 cutting masonite boards into 1" strips, has anyone tried to use a foamcore or Gatorboard instead? You can cut it with a razor, and I'm guessing it would be far less susceptible to warping due to temperature or humidity changes...
I doubt that foamcore would stand-up to moisture because it has essentially a paper cover on each side that could cause warping. Gatorboard may be okay... but Gatorboard is pretty expensive... and not as easy to cut as foamcore.
If my understanding of foam core board is the same as yours - it's a sheet of foam covered in card or paper and similar to what supermarkets use for advertsing special offers within the store - then a fellow over here had an article published in RAILWAY MODELLER several years ago. He'd built a layout using the stuff as the deck and the bracing. It didn't warp and it was incredibly light for carrying into and out of model exhibition halls. Regards, Pete Davies
Gatorboard is a fantastic product to work with, but it is expensive and can be very difficult to obtain in the sizes you want (and when dealing with art dealers you don't always get accurate cuts, losing up to an inch from the advertised measurements). It's like titanium is to aircraft designers. You can cut gatorboard with a regular sharp hobby knife - use the longest one you can, such as the 2" woodland scenic blade. If you are using a hand held blade don't saw it (cut all the way through and then work across) or you'll end up with a damaged edge on the backside. Instead you should progressively slice it to get a nice, clean cut.
