Reply by OggieOglethorpe

  • Advertise with us

Posted on Templates with Extruded Polystyrene Foam

View OggieOglethorpe's profile


1276 posts in 2110 days

#1 posted 08-30-2012 05:23 PM

I used to make model airplane forms with this stuff using a hot wire bow or hot knife. The bow was simply a nichrome wire across an insulated frame, attached to a cheap variable power supply. Here’s a commercial version demonstration of the process. You could also use a soldering iron that accepts a blade where the soldering tip normally goes.

The foam is handy stuff, though. I’ve built reusable door plugs for my spray fan, spray booth wings, taped together full scale mockups of built-ins to demonstrate scale, used it to cut sheet goods on, used it to pad the floor of the truck when carrying prefinished both sides plywood… I’ve cut it on the table and band saw, too.

Another way to toughen up the shape is to apply fiberglass cloth and epoxy to the foam. Brush on a thin coat of epoxy, lay the cloth in the epoxy, brush a little more epoxy on the cloth, and squeegee the excess out with a credit card. You can then leave the foam in place for structure, or add layers of cloth and epoxy, then melt out the foam to leave a hollow form.

DISCLAIMER: Any posts on LJ are posted by individuals acting in their own right and do not necessarily reflect the views of LJ. LJ will not be held liable for the actions of any user.

Latest Projects | Latest Blog Entries | Latest Forum Topics