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Hello I wanted to build a modular dungeon for 28mm (lotr,40k, infinity and super dungeon explore)
I don't like the idea of hirst molds, 30 bucks a mold and you have to sit there and make each piece. Overall it seems like an expensive endeavor. Does anyone have any cleaver alternative? Preferably using pink foam. My concern is making floor tiles. Any tips? I'd really rather not use cardboard. Never works out for me.
Any advice or guidance is greatly appreciated.

My local GW made their board using lots and lots of the Fantasy regiment movement trays. They have two sizes of grid marked out on them (25mm and 40mm as per the two main base sizes in fantasy I think)

The molds are awesome.. I own 40 different ones, so I am bias.. Although if your wanting to make a 3d dungeon you do not need the molds to do it.. Pink foam can make anything you want it to..

http://www.youtube.com/user/theDMsCraft - uses cardboard and everyday Items to make his stuff..

http://www.youtube.com/watch?v=-0nzQrjsezw - shows you how to do the walls and floor tiles out of pink foam..

http://hirstarts.yuku.com/topic/6812/cavern-WIP - This guy made cavern walls out of pink foam to make his dungeon.. He does go into some detail if I remember on how he made them..

Hope it helps.. Dungeon making is awesome when you can actually see it in 3d and not on a battle map.. Your imagination is the only limiting factor..

Thank you guys great advice. The second video was exactly what I was looking for

Foam Core Board is the stuff to use. Cheap, light, easy to cut, easily available. You can even buy it from Amazon.

Rule out movement squares with a felt tip pen. Texture the surface with bits of paper, cardboard, sand, acrylic texture media, etc. Everything can be done with PVA glue. Seal the plastic foam edge with PVA and you can spray paint it with cheap cans of paint, then dry brush with cheap poster paints or samples of household emulsion.