At Home Depot they have giant 4' x 8' and 1/2" thick sections of Styrofoam
I plan on building a Shadow 200 UAV with this foam.
I have to questions to put out there:
I thought of the sheets as a quick and cheap way to make a Styrofoam chassis for an airplane, considering it is only $10.
Do you plan to have some sort of rod running through the inside of the foam? I've put up similar insulation on my house, and this stuff snaps pretty easily. If you were to use this for something like the wings, I would at the least recommend inserting some thin aluminum rods or something, just to act a little like a skeleton and give it some strength. Keeping in the home improvement aspect, I might think of something like these:
Thin, slightly bendable (not too much), and strong. Still pretty light weight depending on which materials you can find them in.
I did not intend to actually. The Styrofoam I bought the thickest type I could buy. I plan on just shading it down to make it smoother and to give it that curved shape.