Thrifty Alternatives ..Building Foam Campers

[eaglesdare]

maybe anyone wanting to become a foamling needs to read this entire thread. sort of like an initiation to join.

[GPW]

A “rite of passage “ so to speak ... I can see that !!!
It won’t take much reading to comprehend that what we’ve all done here is make a “hard tentâ€

[pete42]

I have learned over the years something not known is simple when known.
The first time cutting foam for my airplane a vei-eze was nerve wracking second piece less until finally easy and worry free.
I would think someone starting a foamie would be the same way, one big difference would be if something fails on a foamie you most likely won't fall out of the sky.

pete

ps:
I'll bet if something happens to a foamie on the road repairs are only a big-box store away, try that with a factory built.

[GPW]

Pete, that is most certainly the thought that’s kept me from putting wings on my trailer ...
I’ve seen a few Foamie homebuilts being made, difference is you must do your absolute BEST work on those as your A$$ depends on it ... (LOVE those Rutan designs !!)

Most I could manage now is falling off the couch after consuming the STBU

[swampjeep]

:thinking: maybe anyone wanting to become a foamling needs to read this entire thread. sort of like an initiation to join.

exactly LOL

[RogHodge]

I wish I would have joined earlier- my initiation fee would have been a lot less!

For what it’s worth if you contact Dow or Owens-Corning directly they can help you find distributors and possibly retail outlets in your area- for example;
I spoke with Kate at “blue linksâ€

[GPW]

Rog , since I possess neither charm or good looks , I haven’t had had the same success as you ... Loews and HF were just uncooperative ...

[eaglesdare]

why heck, even Grandma (respectfully considered) could build a Foamie trailer with a serrated kitchen knife, and a pair of scissors ... True !!!
R

hey i resemble that remark! and yes, it does work. but i found using a jig saw works much better. smoother edges. the serrated kitchen knife chops it up a bit (too much at times).

[GPW]

Eagle , no offense intended ... Just a example of how easy this stuff is to work with , compared to wood ... You proved that , Grandma

Over on the airplane forum I run at , found an interesting video , that may be helpful for some... http://www.youtube.com/watch?v=ktKjbefo ... _embedded#! Just more of the same we Old foamlings already know or have experienced...
Is your new MM banner to be displayed like a flag , or just draped over the TD ? It is COOL !!!


Ps. I used a regular old handsaw to cut mine (all straight cuts )... went through it like Butter ...

Psps. I just figured out I’m old enough to be a Great Grandpa ...

[eaglesdare]

no offense taken.

i used a hand saw also after the kitchen knife. it was a fairly new one and yes it worked great. a little too great, as i cut my hand. but that was too much work for these grandma arms, they were sore after cutting out the profile.

a jigsaw is recommended for all foamlings out there! jigsaw foamlings, jigsaw.

[GPW]

Those electric turkey carving knives work in a pinch if you don’t have a jigsaw, It’s that time of year too ... Multitasking ... carve the turkey , clean the fish , cut Foamie trailers out ... But even a cheapo jigsaw works just Fine on Foam ...
Nothing Exotic about building a Foamie , hardest part is finding the darn Foam ...

[bonnie]

Cool video. I think I'll stick with the knife/skill saw method. Though it does bring up a question, GPW, you made/had sanding blocks to help with the rounding. Could you repost those pictures somewhere and explain how you made them? I want to round off the edges of the my build. Seems the coverings would be better that way.

Thanks!

Bonnie
Grandma to one, hoping for many more.

[GPW]

Bonnie , nothing special ... belt sander with 36 grit belt , old coarse wood rasp , and a cheap sanding block, 80 grit , palm sander ...
Here’s what I started with ...
Roughed out with the belt sander

Finished sanding overall with a cheap electric palm sander with 80grit ...

One thing that I would have found Handy would be a long board with a sanding belt glued flat to it , just an extra long sanding block ...


Gotta’ be Careful if you use a belt Sander , it Eats foam very quickly , too quickly ... light pressure and keep it moving seems to work best ... the wood rasp worked for the initial rounding , was much safer and predictable , but just a Lot of sweaty work ... it was a Hot summer so we wanted to get it done as quickly as possible ... belt sander ...

[GPW]

BTW, The sanding can make a real difference in the finished appearance... the Better you sand it , the smoother it will be ... My sanding wasn’t the best and I can see minor imperfections under the canvas telegraphed to the surface ... Just like a good paint job really , the prep is Everything !!!...

Thinking back now , I could have gone to 220-320 grit and had a much Smoother surface ... I will do that on the Next one ...

[pete42]

Has anyone tried using foam against foam as a sanding block?
I seem to remember when building my airplane we did something foam against foam.
I have lost so much memory I'm scarring myself.

Pete