My latest is a 19 x 20.5 incher from FFF at 10 oz and a loading of 4.0 oz. sft. Porky, but, boy oh boy, does it perform. Komodo power on 3S for instant thrust, that equals pure sinful joy. I went from a 2S setup at 7.9 oz/3.2 sft just because, or maybe it's just because I like to be bad. The lighter version was heavenly, the heavier more devilish
No need to fiddle around bending foam, just glue it to the top of the airfoil shaped fuse starting at the front using hot melt and work you way to the TE in short stages. You can do the whole process while holding it in your hands keeping the pressure on while the glue cools. The bend in the foam adds tremendous strength and having it under tension keep everything straight. No need to make a simple thing complicated.
Run the ripple span wise when using FFF and for Depron, keep in mind it has a grain.....as in it bends one way better then the other.
Changed my mind on the 13 and went with a 14, shooting for 3.5 ounces for a hallway flyer.