As I promised, here are the photos of my first Styroplast samples.
This picture is Styroplast over several of the different "cloths" that have been mentioned as possibilities for the "sock"
I brushed on a real thin coat of Styroplast (maybe 1/64th or /32nd of an inch) over each of the different materials. Each swatch of material is glued down with Foam Fusion from the Hot Wire Foam Factory. I'm pretty pleased with that product. The Styroplast sticks like crazy and won't be coming off unless you destroy the foam. The end result is a very smooth coat but somewhat uneven. I asked hwff about this and they replied that there is a bit of technique (artistry) involved in getting it even and they do recommend the use of a trowel to apply the Styroplast. You can also use a brush. You'll need to use acetone to clean your tools or just buy disposable tools and don't worry about it. I used a cheap china bristle brush on the sample and that's pretty apparent.
The next picture is of a corner of the foam I applied the Styroplast to. I also glued down some mesh with the Styroplast. It works, but not my favorite method. I'll use the Foam Fusion.
I let the sample cure about a day and a half and gave it a good thump with my knuckle. As you can see on the sample, my knuckle broke through the thin layer I had put on. I tried to do the same thing with the samples laid over fabric and all I got was a sore knuckle. The Styroplast is flexible though. I squeezed the corner of the foam to see if the Styroplast coat would crack and it does not.
So here are my thoughts. I will glue down fabric (probably fiberglass) with the Foam Fusion. I'll put a layer of Styroplast down over the top of that and that should provide me with a strong, flexible and smooth outer shell.
I'm playing with a larger sample and going to do my roof to wall join and see if I can get everything to work out nicely. Pics on that as I get that done.
In the meantime if you have Styroplast questions, go ahead and ask away...