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Making a PU board with intention to reshape later

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Observations:
A) Last time I did this I found the rails were the worst to take off - that's where I lost the most foam.
B) If you burn PU resin the glass comes out good as new. It only comes out black if you're burning it with carbon. I guess this is polluting and the glass is weakened... but it seems like an interesting effect

Questions:
1) How can a PU board be shaped so that the blank inside can be more easily recycled into another board later?
2) In recycling blanks, did you find some glass comes off easier than others?
3) expanding foam is generally not advisable but it has been used alright under wood veneer... at what point is it ok for a bit of hole filling and when is it not? I filled some holes with chunks of foam cut off the tail last time... perhaps a bit of spray foam filler on a test board is ok...

Since I can't get EPS, entropy bio resin, nor PU blanks in Hong Kong, this is for personal boards I fly in with but the main reason I'm interested in this is I don't like waste


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