Here's one days work with my brother laying down some foam. We ripped the 3/4 in thick Core Cell foam into ten inch wide planks and thermoformed each plank by using the ten bulb easy bake oven seen on the left. With the oven settling out around 175 degrees F, I found that seven minutes ( no more no le ss )resulted in a nice soft plank that followed the stringers very well.
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and the 7 minutes give enough time to gather and prep all those little plywood squares that act as clamps. Each square is abou 2", and you start a drywall screw into them, stick a square of plastic behind them to keep them from getting glued, and put them all in a row that's easy to reach so that you can get at 'em while you're trying to hold the thermoformed plank in place. It goes pretty quickly, all in all.
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