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Any foam-core modeler will tell you that it’s important to make a corner that looks flawless so you can easily paint it and finish it out.  A good way to do that is to use a rabbet cut — a notch cut along the length of the edge in question — to mate the two pieces.  The bad news?  Cutting rabbets in foamboard is a pain — unless you’ve got a foamboard rabbet cutter like this one.

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