

Having curved thinner foams in the past for model planes , I know it can be easily done by the heat method

I’ve thought a long time about how to bend 2” thick sheets of foam and how to heat up a large area uniformly ... And then it hit me ...






Now if we cut a foam sheet into 2’ (or less) wide X 8’ long sections, we can have easily bent/ formed pieces , heating only a 24” wide area (easy) making the bending easy , and allowing sections to be stacked together for Wider trailers ... The narrower pieces so much easier to handle , and the foam , being homogeneous material (no grain) easily glues together to form a larger structure , somewhat like Legos . A simple bending form could be built of wood scraps and such , wouldn’t be that big , and could be disassembled after using .. Heating could be done with a simple HF heat gun , or two (front and back at the same time ) which would be pretty quick and efficient .
Pictured below is a simple Proven type of jig that allows foam to be bent in marked increments allowing graceful curves over long distances.. Many ways to build it .. easy to use... and in 24” sections would be downright Quick and Easy ... for Two people ...
Ps. a temporary full form of the curvature could be built to allow for repeating as many identical sections as you want ..

