thanks for the pointer WandrinAndy, i'll have a good read through that..

blackburn mark, I can't ever seeing me wanting to cut anything other that foam, maybe some 2mm ply, was hoping that if i kept it to these materials it would keep the cost down.

John S, never thought of a laser, i'll look into that, would that involve more cost..? I haven't got a big budget..

Thanks for the replies..