Matt,
My hot wiring was simply to reduce the 150mm thick lumps of foam to more sheets of 25m and 50mm foam.
As for the board the path is:
1) Print profiles form Rhino with 1mm contours, stick to foam.
2) Route profiles from either side.
3) Sand to shape
4) Cover in carbon (uni then weave)
5) Fair with BOG
I think your route sounds similar, just you have
2a) - stick two halfs together
4a,b,c) add unis, fair, add weave, fair
It might be that Phil was commenting on part 4?
When done I'll post the weight of the boards I'm making for eveyone to laugh at (lead stringers), but if I can be of any help with your routing pattens via Rhino then please yell. Might be ignorance, but failed to make profilli do anything like the jpg attached.