Faux Balustrade

[BSchend]

I have to make 2 six foot long sections of balustrade for an upcoming production of Hunchback. Looks like this
http://a404.idata.over-blog.com/600x344/0/18/21/95/Paris/Notre-Dame/Chimeres/chimeres69.jpg

Obviously I'm thinking foam for the central quatrefoil portions, but not sure the best method to go about getting a clean reproducible (and double sided) result.

My first thought was to use a template and an angled sled for a hot knife. Best foam (eps or pink/green) or hot knife you'd suggest for this? I have both kinds of hot knifes (single rod Hotwire Foam Factory, and carving knife style knife).

Thanks for any input.

 

[JonCarter]

How far is the closest audience seat from the balustrade? If over 35' or so, jig saw it out of 1/4" ply or Masonite & have your scene painters do the 3D effect. Nobody will know the difference.

 

[BSchend]

there are about 75 seats within 15' of the pieces. Another 250 15' to 50' away.