You can cut the styrene with a metal ruler and razor blade by scoring your cut line with the razor and ruler and then bending the styrene and it will snap off where you scored. Use some sort of brush on plastic weld solution for model kits like Plastruct and it will permanently bond the styrene supports to the vac form shell (which is also made of styrene).
Would work best on the flat surfaces, but could get creative with how you do the supports for the nooks and crannies.
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