The problem I see with cutting up a glued brick of cardboard is that the bandsaw blade has to be REAL sharp and have a large TPI. Chances are that the edges will also fray giving a fuzzy cut. I can try that, I have a huge bandsaw handy in my shop. I may just decide to cut it out by hand, gluing 2-3 layers at a time and then gluing those together with other 2-3 layer pieces and getting a thicker part each time. I’ll try wood glue, since I have plenty of it. Planning to roll it on with a paint roller, should give me a consistent glue thickness compared to brush.
Thanks, Brendan