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One of my eventual goals is to make a modular terrain table.  One thing that worries me is getting all of the pieces to be sized identically so that they fit together properly; what's the best way to do this?  All I have is a circular saw, and it's not good enough for work like this.

Thanks!

What I'm planning is to do on my own attempt is use metal rulers or a good T-square to serve as a guide for a hot knife or wire to cut the rest.

i use a table saw get ur self a piece of very thing plywood like 1/4 in thick the thinnest stuff you can find, glue that too the bottom of the foam sheet makes it a lot easier to cut on the table saw or circilar saw and framing square is need.

I've started actually working on my own board, and I've got some good tips for people planning trips to the store.

1) For the sheet styrene, Loews (and I'll assume home depot) was happy to sell me several 10'x12' sheets and then cut the sheets down to my specifications. They used the same woodcutting station they use for boards and sheetrock, so if you have a gentle clamp or guide set up on your workbench you can probably make it work.

2) The styrene will have a thin plastic coating on each side. Take it off before you paint, or watch 10 minutes worth of paint slide right off the board along with the plastic.

3) If you mention you're going to paint it, the hardware guys may try to sell you on the plastic-bonding enamel spraypaints that a lot of Nerf modders like. Don't do it unless you're building a moonscape board. The spray propellants from these will pit and chew up the styrene just like normal sprays or primers. Just buy some regular cans of paint and foam brushes.

I'l going to try to put some WIP pictures up once I have more than 1 board section painted.