If you have a band saw/foam saw/meat knife, cut the corner off all the way down and then finish off with a grinder.

You can also layer the foams so that the last piece glued on is rolled over the one underneath it, it would give that rounded look without even grinding or cutting anything if that makes sense

It does. thank you for the response.

you got it, goodluck!

You can also try cutting out and removing an 1.25 x 1.25 square. Then glue the two remaining edges together. I find on a long length it gives an even curved shape.

@Eric Gordon I wouldn’t have thought of that in a million years. I would have gone with the first route. Thanks for the share

You're welcome Cody. Another thought I forgot to mention, as seen in the pic, is to mark with a sharpie and leave the line after cutting. It gives two straight lines that after gluing you can follow to easily pinch the foam together.

That is brilliant. Thank you.

What I used to shape hard foam is a tuna or sardine can and poke holes with a nail it makes a nice scraper....

I use quart paint can lids, with nail holes in them.

The more firmer the foam the better it comes out..

A sincere thank you on this!

I have turned jobs away in the past because I was afraid to put out an inconsistent radius.

I will not turn them away again!

Thanks again,
Eddie

I definitely will try this!

I use a cheese grater thats used in body shops to shape my foam. Works great every time

@Eric Gordon Great tip! Really good! I haven't seen that yet. I will try it at the next opportunity. If there is too much glue, the edge will be hard, but most of the time there will be a cushion over it.
I work with 3 different knife lengths with the Bosch foam saw. With it I cut everything into the rough shape. I do the finenesses with a compressed air grinder. If you've never done it before, it takes a little getting used to, but if you're used to it, you can get extremely fast.

I use this for shaping foam, also it works great on headliners.

I use a ton of sanding blocks, 40-80 grit paper. Roloc sanding discs, and a trim router. Router bits cut foam like a knife through hot butter. I have roundover bits to 2” radius