Jake,

I always put on a layer of epoxy thickened with collodial silica on the foam first, to fill all gaps. Then I put on the glass and wet it out. I hope I save some weight that way and still have a good bond..

I have used a rigded alu roller, but found it to be too messy. For thick laminates it can be nice, but most parts on cats are so delicate that I prefer a squeege. Squeege and vacuum is my preferred method.