Foam cutting and foam coating

[samcrow]

Hi all, while I have been on the forum for years, I am rather quite. I am finally starting an ironman foam build after years of looking and just wishing I had one.

With all that said, one thing I have been looking at is the cutting if foam. Using scissors usually makes for not the smoothest edges. Using razor knifes or blades eats them up and takes lots of work.

So tonight, I thought I would try something different. I went out to the garage and grabbed some 1/2 inch and 1/4 inch EVA foam. I then went over to the bandsaw and found that my standard wood blade just cuts the foam like butter.

So as I start the build, I will post pics, but could not believe just how smooth and clean the lines were. Also, because its adjustable, I can do angle cuts. Not to mention, it cuts so smooth, that you can trim the slightest edges off.

I do want to thank everyone who posts on this site, without you, I would not be building at all.

Another thing just to bring up. I know there have been multiple posts on sealing, coating, covering foam. While I do not have time this season to do it, something I want to try is worbla. It's a plastic coating that you heat and form and can do over foam. Just wondering if anyone else has tried worbla coating over foam to give it some hard covering?

Wil be posting soon. Again thank you all for all the tutorials.

 

[ZukutoSkyKiller]

I'm looking forward to seeing pics. Especially of the saw you are using

 

[samcrow]

I'm looking forward to seeing pics. Especially of the saw you are using

It's a standard ryobi 9in bandsaw from lowes. The beauty is that it cuts from the blade side as well as the back (smooth) part of the blade. I'll have to get some pics up soon.

 

[vargatom]

Band saw is probably pretty good, but makes it hard to make angled cuts.
I've read about people using laser cutters, hotwire cutters, hot knives (basically soldering iron with a blade that's heated) ...

So far what I've been using a simple X-acto knife and I've bought a 100-blade pack. I replace the blade at least 3-5 times per 60x60cm foam sheet.
It depends on the size and number of the pieces - smaller pieces -> more pieces -> more edges overall.

 

[P4r4dox86]

I have done some tests with Worbla on foam and it's worked quite well. I haven't attempted a large piece yet, but my next major build will likely be using Worbla on foam, so I'll make sure to post my progress in a thread when I get around to starting it . Good luck with your build!

 

[Dirtsen]

Looking forward to some pictures of this. I always like to try out something new!

 

[Lord Atrocity]

i am currently using worbla for my darth revan armor and its working out really well. the only issue that i have is if you heat it up to much it actually picks up on every little dent,bump, cut and dimple. worbla is a great product dont get me wrong but if anything i would look into wonderflex. you can pick it both up at
CosplaySupplies.com -- Search Results

wonderflex has the same properties as worbla but the finished side looks a little better in the end game. either way you can throw on modpodge or wood glue to seal things up. any other question just pm me and ill see what i can do for ya

 

[igs]

All great tips, Thanks guys this is the stuff I'm looking for here.

 

[samcrow]

I will be working soon on it. Just made the duct tape dummy to help with fitting parts and holding them together.

I have less than a month before a school fundraiser to try and get this done.

oh the joy!

thanks for all the info shared on this so far on the worbla, I am in the states and it is hard to come by here. But it sure seems that if you do a foam build and then put it over it (while not cheap), will be a really good solid surface with some flexibility.

 

[Looch]

I built a hotwire cutter to cut foam, but have also been working on a way to attach a dual-bladed ham slicer.

 

[Robert69]

I had wood burner with a edged utensil and I just tried it on a scrap. It cut nice and smooth. Stinks in here, but a small price to pay to get something that looks good.

 

[Ragz]

I built a hotwire cutter to cut foam, but have also been working on a way to attach a dual-bladed ham slicer.

Was your hotwire cutter just a couple batteries and a cord (like a thin guitar string)?

 

[Looch]

Was your hotwire cutter just a couple batteries and a cord (like a thin guitar string)?

It was a bit more than that, actually! The housing is tall enough for me to use without bending over, and the tabletop is on a pivot system so that I can tilt it 45 degrees when I need that kind of angle. The power source is a model train transformer with variable DC output for regulating the heat. These are pretty-much the only pics right now, sorry.