I bit the bullet and bought a new router and set it up on a piece of 3/4 plywood as a router table, albeit a little makeshift. Did a couple of pieces and it worked well enough. I think I am going to put in a fence though, the foam is soft and running the edge using the round over router bit bearing and getting it perfectly consistent is trickey freehand. The fence will help a good deal with that, for strait edge pieces at least.