Thanks for the questions and ideas and the EVA name.
The Hobbycraft foam is only 2-3mm thick but the eBay link is on its way to me.
As for armour - not at my age
As for the need - given I have done nothing with games for the last few months (well Feb at least) and have not really wanted to I decided I would revist
this project but in a
Portable Wargames 8x8 format as a trial to see if I am up to this...