Sharing tricks from my build experience while working with foam and Great Stuff glue foam.
I needed to glueup curved panel that was previously kerfed. I decided to use GS for its light weight, same density, lower cost and good adhesion to foam.
As a result of trial and errors on sample (and non-sample

) bent glueups, I came up with these items to make for a better curved foam wall panel:
1. Plywood edges were glued (w.TBII) to make a consistent bent along the panel length and assemble the panels together. They are light, 1/4" thick and contribute to a stronger wall structure.
2. Custom clamps. I premade a batch of plywood brackets like these so they can be screwed on some scrap lenghts of wood to position the curved panel both edges at precise required angle. It is very quick now for glueup clamping or rather "clicking" in place.

3. Packing tape placed on foam. I did it after the kerfs were cut which was a bit of work. Next time I plan to put the tape and then cut kerfs.

4. Great Stuff canister tip *modification* or simplification.
I simply removed the stock plastic tube from the plastic adapter on the can and this simple trick made the placing of GS in the kerfs SO MUCH EASIER, cleaner, quicker, and in a right amount. You'll wear gloves, right?

?

5. The glueup result: no sanding is needed.
Panel is clean off GS, nice and straight.
