Web Sites w/ Foam Info For Tools, Techniques, Sources Etc..

[KCStudly]

Cut wide and sand to fit. Sands quick and easy with a hard block. Keep the shop vac handy, tho. It gets messy fast.

[be_a_jayhawk]

Gotta put this up. I bought this hot wire cutter at Hobby Lobby for $35. It's made for pretty light craft foam so I thought I would tear it up and have to return it after one cut, especially since they didn't have any replacement wires for sale. But it worked like a hot knife through butter. I only used one wire (it did come with 3) to do all of my curves. The unit does come out of the base which is how I mostly used it. I highly recommend it.

[lthomas987]

So, I've been cutting notches in foam with a piece of copper ground wire bent to shape and run through a block then attached to a 100W solder gun.
I have need of cutting some wider notches than the ones I've been using, and I got to thinking.. could I use a hack saw blade? Bend it to the shape I want, then somehow use the copper ground wire to attach it to the solder gun. Would it get hot enough? Anybody got thoughts on the issue before I start experimenting? I mean I could just make 2 passes with the cutter I have but I could also make a new tool.

[wagondude]

Probably would not get hot enough without passing some serious current through it. The other problem is hack saw blades tend to be kind of brittle and break easily when bent ( at least the cheap ones).

[rivernstream]

I was reading through this with great interest especially on the stryoplast vs foamcoat w/bounce discussion. And elsewhere I think in the big thrifty thread there was a discussion of zoopoxy which is non toxic similar to the HWW products. Did anyone use these on their foamie?

I'd be thinking about something like this for the roof of my woodie foamie still in design. In my research I came across this Youtube video that uses PVA glue to seal the foam (as in Weldbond or titebond 2/3) and then a molding plastic Smooth Cast 65D. Actually there's a lot of material out on this topic related to cosplay (costume) and set building which uses EPS foam extensively.
Smooth on, the maker of Smooth Cast makes a variety of products that could have application for foamies. Smooth cast products that provide different hardness, working time etc... run around 85-100 per gallon. all are self leveling. Sandable, paintable. Might be a good option.

https://www.smooth-on.com/

65D what's used in the video http://www.reynoldsam.com/product/smooth-cast-semi-rigid/?gclid=Cj0KEQjwzpfHBRC1iIaL78Ol-eIBEiQAdZPVKmq64GoHaLJ9pwr6PSqqVvma123voxOawQS9X1jrlQsaAprK8P8HAQ short working time.

300 series http://www.reynoldsam.com/product/smooth-cast-325/ more for mold making or casting but can be used for laminating longer working time, can be colored so no need to paint after.

Here's info on the colors https://www.smooth-on.com/category/color-and-fillers/

Smooth On also makes an epoxy for directly coating foam that also has no VOC's. and provides similar to stryoplast. http://www.reynoldsam.com/product/epsilon/# Looks like coverage at 1/16" is 30sf per gallon. Here's the description Epsilon® is a two-part thixotropic epoxy coating that self thickens for brushing onto a variety of surfaces without sagging. This product was developed for fabricators that regularly coat EPS foam. Cured material is easily sanded, primed and painted. When applying to vertical surfaces, Epsilon® wets out uniformly. Only 2 layers minimum are required to build an adequate thickness and provide an impact resistant coating. It can also be applied to plaster, concrete, wood and fabrics. This product is not sensitive to moisture or humidity and contains no VOC’s.

This one looks like ZooPoxy -- UreCoat® is a two component urethane (A+B) that can be mixed and brushed onto a variety of surfaces to provide a flexible, tough and impact resistant coating. UreCoat® will bond to many surfaces and can be used as a flexible coating for expanded polystyrene (EPS foam), fabric, some metals and plastics, wood, rope (make vines for zoo exhibits) and more. Cured rubber is tough and UV resistant. http://www.reynoldsam.com/product/urecoat-coating/

The helmet looks a bit like a tiny teardrop doesn't it?


I will be experimenting with this product to see if it provides a good solution for me.