Foam + Bondo Question.

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JokerOfArkham

New Member
I'm currently working on a foam Starlord helmet and was planning on using bondo to smooth out some of the edges where the foam meets. I know that bondo isn't recommended for foam as it's not exactly flexible. I figure though that for a helmet, it doesn't need to be overly flexible. My main question is this: Should I use plastidip before applying bondo or should I apply the bondo to the foam then plastidip the whole thing?
 

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Fireman Dan

New Member
Hey Joker
Try this product called Epsilon from Smooth-on products. It's perfect for foam. It will harden your pieces and can be sanded and filled with spot putty. The product is self leveling, but I recommend using a good paint brush when applying
 

JokerOfArkham

New Member
Hey Joker
Try this product called Epsilon from Smooth-on products. It's perfect for foam. It will harden your pieces and can be sanded and filled with spot putty. The product is self leveling, but I recommend using a good paint brush when applying
Thanks for the suggestion!! I'd be totally game to try it out, but I'm trying to get this done before May 2nd, so I don't really have the time to order the Epsilon. I'm just wondering if the Bondo will adhere properly to the foam or if I would need to plastidip it first.
 

PolyversalAri

Active Member
As someone who has personally experimented with Foam / Bondo it is not an ideal combination, but it will adhere if you rough up the foam edges a bit first.

If you are going to try this method, definitely Plasti-Dip last. I think that Bondo over Plasti-Dip would make it more likely to fall apart since Plasti-Dip is meant to peel.
 

Fireman Dan

New Member
Another solution is to make Rondo. A mix of 50% Resin and 50% Bondo. I know for a fact it will stick to foam treated with plastidip I recommend you work in small batches and wear a respirator.
 

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Mikki Haight

New Member
Rondo for working on a budget. Smooth-On's XTC-3D also works on foam but it won't build up like Epsilon does, just gives a fairly hard (albeit thin), glossy surface. I tried straight Bondo on resin-coated foam and the bondo all curled up at the edges. Always test on a scrap piece when in doubt. Good luck!
 

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