RE: the difference between foams???
the extruded polystyrenes are nice and consistent, unlike the beaded foams that have all the gaps and air pockets between the beads. they're usually denser and need a little more heat and a slower cut speed.
i make most of my wings from a stiff 2.2 lb. foam. after cutting it has a very nice and smooth finish that can be used as is for the small planes or paper wrapped if i need a super strong wing.
dave