I read about polystyrene leaching chemicals on the dendroboard forum. But, I have yet to see any evidence that it affects reptiles in terrariums when they are properly sealed. As I won't have any standing water in this build, and as I have a false bottom that will quickly drain the majority of water that gets down there, I really don't think this will be an issue. But, I've been wrong before.
Anyway, I went ahead and carved my background once the GS dried. It turned out alright for my first try (or second if you count the failed styrofoam experiment). Since the windchill is about -40, I had no choice but to do it in my apartment and make a mess, again. It wasn't as bad this time, and it vacuumed up quickly this time.
My next step is to get it siliconed into the tank. I'm going to have to do some cutting of the material as it doesn't quite fit. I'll also have to GS the meeting point of the two boards to ensure it is completely sealed. Then I can put the TBIII and coco fiber mix on. I'll probably GS in a few plant holders as well.
Anything else I should worry about before moving forward?