I posted a year or two back about my experiment with making roadbed out of Funky Foam or Funny Foam as it is sometimes called at Hobby Lobby. It sells for $ .99 for a 12 x 18" sheet and comes in several colors (dark brown, tan, grey) that serve as a good under color depending on what color ballast one uses. I cut it in narrow strips in a jig I built and cut it with a carton knife blade mounted on a small wood block with small screws. The blades protrudes below the block just the thickness of the foam (3 mm). I made two of these: one with the blade angled at 45 degrees for the side of the roadbed and one at 90 degrees for cutting the side that meets in the center much like cork roadbed. The foam bends easily on curves, adheres with the clear dap caulking and accepts traditional ballasting methods without deteriorating. It is denser than the black foam roadbed that comes in rolls so holds nails better and has a sound dampening quality. I get about 14 strips out of a sheet which makes slightly more than 10 feet of roadbed or $.30 for a three foot section. Pretty economical for those trying to save money for other railroad needs.
The foam is slightly thinner than cork roadbed but scales out to about one foot thick which is the average depth of ballast I researched on one prototype sight. The only thing I cannot verify is how it will hold up for the long term although my initial installation shows no deterioration after two years. I have decided to use it on my expansion based on the performance I have noted so far. Just an idea that may help others on a budget. Good railroading!
