RE: Building a large foam plane
The best thing you could do is try to find a book by Keith (Sparky) Sparks on building in blue foam. My local hobby store a copy on the shelf a couple of months ago. He wrote several articles that featured foam airplane construction. I met him at the Small Steps fly in over in Dallas when Randy Randolf ran it. He is a nice guy and made some neat planes. His planes were covered with clear monokote and scuffed up with sand paper and painted with monokote paint IIRC. I think he is a member here but I haven't seen a post from him.