I'm using a 'generic' 5mm foam board available through Ebay in the UK. It's quite a bit heavier than DTFB, but when I started building using the Flite Test plans about 3 years ago, I was completely unaware of the weight difference. All my planes flew, but as nobody at the time was posting All Up Weights, I had no idea mine were heavier.
When I eventually became aware of the difference I wondered what all the fuss was about. But I did start to notice that some people were flying their DTFB planes with what appeared to be much larger battery loads. Where I was using 1000mah and 1500mah, they were using 1500mah and 2200mah. So basically, many DTFB fliers were flying on roughly the same AUW as me, or could potentially. They were getting a little longer in the air - so what I said; if I take plenty of batteries, my flying session can be as long as I want it to be. And if the DTFB planes are flown lighter, it means they can fly a little slower. Though you wouldn't think it from the videos I've watched, most people seem keen to go as fast as possible! I've got friends who have built the mini series with heavier foam board and have been very happy with the flight experience. It flies - wow! That's usually enough for a beginner
Regarding the difference in the foam's thickness, when cutting out plans it's almost as simple as where you cut along the line. Printed-out, some of the lines are actually quite thick, so if you cut down the middle of the line you get one size; cut along the edge you get another. Once you're familiar with your board, you tend to get a feel for it. I transfer the plan to foam board using pin-pricks, and then redraw the plan on the surface paper. I'm probably mentally readjusting the size of any fold-joins and tabs as I go. Only a few of the joins are actually 'critical'. Though even then a sloppy join is easily disguised with an extra film of glue. And if it's a touch tight, a little pinch of the fingers to slightly flatten the foam will usually let things come together. It's really not rocket-science.
In October 2013 I posted an article about 'heavy' foam board;
http://www.flitetest.com/articles/don-t-let-heavy-foamboard-get-you-down
It 'showcased' all my heavy foam board builds, and since then I've built a whole range of planes using heavy foam board, and though I might be a little envious of missing out on super slow speed flying, I've produced some very satisfying and slow-flying builds.
My advice, don't fret the weight of the foam board too much. Build-up your skills, both in flying and scratch building, to the point where it matters, and then start exploring ways to improve your builds. But I'll draw your attention to a comment by David Windestal during the spitfire build, where he suggests extra weight is a bonus, helping the plane with wind penetration. Some of these really light planes aren't worth taking to the field if the wind is over 5 mph.
Cheers, alibopo.