Thanks to everyone who replied - I will try the walk stitches and the pushing of the foam. We did increase our density, but not quite to double - I am going to try that also. I guess my assumption was right - foam is extremely labor intensive - whether you know what you are doing or not. How much extra does everyone charge for foam - do you just figure your total time in, or do you upcharge because you are doing foam? Thanks for all the hints! Melissa