Mike I really appreciate you giving such a detailed response...you confirmed all my suspicions.
Without going thru all your past posts on the subject, did you add a liberal amount of glass bubbles to your epoxy to glue the foam strips together? I have had good luck in the past sanding the glue joints in H80 when you really load up heavy on the glass bubbles.

Thank you again for your generosity in sharing your experience.

Best Regards,
Robert