Looking for some advice on sculpting foam

[ETFerguson]

Hello everyone, just had a quick question as I'm running into trouble with a couple projects I'm currently working on. I love using foam, it's a gift for building armor. I have stepped my costuming up a notch and have been looking for a good solution to rounding edges and cutting small angles with foam. basically what I'm looking to do is have the edges of some of my pieces angle down or round off so they meet the underlying piece flush, instead of having all 90 degree edges. I recently purchased a hot knife which I'm loving by the way, but it still only helps to make precise cuts and doesn't aid in the edging department. My next idea is to buy a small rotary tool like a "dremel" to try and sand down the foam edges although I have a feeling it might just tear it all to bits. Any help would be appreciated as I have searched and browsed many threads to do with foam builds on here but have come up empty.

Thanks!

Elliot :thumbsup

 

[EyeofSauron]

An idea I had is to soak it with water, freeze it, and then sand it. I don't know if this will work but it might be worth a try

 

[spydrwebz]

EyeofSauron's idea and fine grit sandpaper just might do the trick. I know that 160 grit will tear it to pieces.

 

[the_batdemon]

If you're talking about EVA or mat foam, I don't think that soaking it in water and freezing will help, as it's a closed cell foam. For open cell it does. We use a DA at work to round corners, but are also working with 1" foam.

Look into mat board cutters for angle cuts. A rotary tool with a drum sander on a lower setting will work. Test it out on scrap to get the setting. I've found that you should sand in one direction or it might catch the foam.

 

[LeDragon]

I am looking into doing this also. I have a dremel and all 'most' of the attachments but I am reticent to break it out in the house because of the noise. Everyone's happy your making costumes till you start to hear,.. "Whats that smell..." or "What a mess."
I am looking to use this technique on the edges of a foam Master Sword for my sons Link costume. I bought a soldering iron to maybe try and burn or melt the eges of the sword blade after I cut them and sand them.

 

[ETFerguson]

Thanks for the info guys. I also don't think the freezing option will work but who knows I may give it a shot. I think I'm going to buy a rotary tool, there's a small one at my local craft store (Michaels) that's like $30 so I may as well buy it to have anyways. It has a few different attachments and I know it has the drum tool you're talking about batdemon. Any other ideas feel free to reply here or drop me a PM.

Thanks!