Over the years, I've built benchwork from plywood and Homasote, extruded foam alone, extruded foam glued to hollow core doors, etc.
I want to build some light weight layout sections and I'm thinking of laying out a grid of 1X2s, attaching a layer of thin lauan (luan?) on top of that, then laminating a layer of extruded foam on top of that. Then I'm thinking of using another layer of lauan for roadbed. I've tried WS foam and obviously cork and I'm not excited about Homabed ($$$) or ceiling tile (possible inhalation hazard).
Opinions? And how does one bevel lauan roadbed? I do not have a router.