Originally Posted by
joe greiner
The end mill SOUNDS like a good idea, but for 2.5" cutting length, the mill would have a shank larger than most routers accept. Since the foam is a lot softer than materials usually used with an end mill, you could turn the shank down to 1/2", provided the mill is dedicated only for that application. Next issue then is to find a router with sufficient plunge depth, and it might be necessary to modify a conventional one. And even after all that, there's dust control.
Joe