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5.0  Installing the Styrofoam Surface to the Module Frame
Remember that we bought one sheet of 1½"x 2'x 8' butt-joint styrofoam (if you couldn't  get a piece that was 4' long).  Styrofoam (or extruded polystyrene foam board as it is technically known) is typically blue or pink in colour.  It's the stuff that's used in insulating commercial buildings or the inside of the foundation on your new house (if you're live in Canada, you know exactly what I'm talking about!)
Don't buy the white stuff! The white stuff is not styrofoam.  It will not support trackwork, wiring, switch machines, scenery, etc.  Only use styrofoam. 
If we assembled our module frame together properly, we should have a frame that is reasonably square and has inside dimensions that are 22½" wide and 46½" long.  If we take our time, carefully lay out the work, and use a bit of patience, we can easily cut the styrofoam to fit snugly into the module frame. 
5.1 Cutting the Styrofoam to Length

This kind of work is best done outside as cutting styrofoam results in a lot of pink crumbs.  I use my picnic table as it provides a nice flat surface and the grooves in the top make it easier to cut the styrofoam. 
  • Lay the sheet of styrofoam on a flat working surface
  • Using your tape-measure, mark off and draw a line that is 46½" from one end of the styrofoam sheet. 
  • Place a straight edge along this line (I used my carpenter's square) 
  • Use the smallest-tooth saw that you have (this may even be a hacksaw blade) and carefully cut the styrofoam along the line. 
  • It's best to overcut than to undercut as we can easily trim any overcutting.

5.2 Cutting the Styrofoam to Width
We now have a piece of styrofoam that is 46½" long and 24" wide.  We need to cut the styrofoam to 22½" wide. 
  • Using your tape-measure, mark off and draw a line that is 22½" from one side of the styrofoam sheet. 
  • Place a straight edge along this line (I used my carpenter's square) 
  • Use the smallest-tooth saw that you have (this may even be a hacksaw blade) and carefully cut the styrofoam along the line. 
  • It's best to overcut than to undercut as we can easily trim any overcutting.

We've now got a sheet of styrofoam that should fit snugly into our module frame.  Try and brush as much of the crumbs off of the sheet.  Don't discard the scraps as you've got enough styrofoam for another module with something leftover to make some mountains. You may need some slivers if you've undercut the styrofoam. 

At this point, you're all set to fit the styrofoam into the module frame and start laying track.  Resist the temptation!  Styrofoam that is snugly fit into a module frame won't be snug for long.  We now come to the part which requires a bit of patience.  This is where we'll make the styrofoam and the module frame into one complete solid unit.