Sandable high density foam

[spudchucka]

Worth a look

Its used extensively by manufacturers of windsurfing boards.

http://www.carbonart.co.nz/#

You could always give Jimmy a call for advice.

[imdying]

Ah ha! I'll ring a local shop first, see where that takes me

[imdying]

Apaprently I want Rigid Polyrethane Foam, 32kg density, available from Forman Building Systems, 0800 45 4000

[imdying]

Yes, Formans have it, although not in stock. You just need to tell them what size you want it cut to, and they'll get it. They also have a higher grade (F or H or something) polystyrene which is cheaper than the Polyurethane.

[Crisis management]

Be aware of the differences between polyuretane and polystyrene...polystyrene is a whole heap of little balls stuck together while polyurethane is a "solid" foam.
Depending on the finish, you want you may be better off with the polyurethane. It will sand to a better finish while the polystyrene tends to leave a rougher surface as it "sands" by losing balls out of the surface rather than abrading material off a solid mass.

Does that make sense?

A cheap option may be a scrounge around a commercial building site, there is usually tons of offcuts lying about. Ask and you may be rewarded!

[imdying]

Yep.. the rough surface left by those balls is my problem... takes too much body filler to get it smooth again! (I've been using polystyrene).

[jade]

go to a boat building yard for some high density foam - or hi mod

[IamCornholio]

Hey just a thought, I have used an expandable foam from a can over an existing panel to form cheap mould.
Highly polish and use of releasing agent you can apply foam and spread out with spatular, set in pre-cut carboard ribs for extra strength.
All depends if you have a good panel to start with.

imdying quote as well (because I read it all before I posted...) "Yep.. the rough surface left by those balls is my problem... takes too much body filler to get it smooth again! (I've been using polystyrene)."


I thought Kflasher had some good advice friend. Some of the spray can stuff can very quickly form a 'workable' mold for building up panels and such stuff... So long as you use the releasing agent correctly you can easily build up a mold with this stuff if you have a sort of pattern to go off of for building up your mold...

As far as the polystyrene stuff... Are you shaping it with a sander or a knife or what? Let me know exactly what you are trying to build here so that I can help you out if I can friend...

Tell me a little about your project here soas that I can help if possible... I saw your name on the thread and had to try...

You are a friendly and helpful fellow here at KB imdying. If I was a girl, I would give you some pu**^... Sadly, I can't really DO all that so I will just do my best to help you with your project instead...








IamCornholio

[Kflasher]

You can use this spray expandable foam for heaps of uses apart from it's intended use.
i.e. To build a custom air box I placed a rubbish bag on top of engine, placed tank back into position and then slowly filled rubbish bag with foam. This gave me a pretty good mould of the space I had available to use.

[IamCornholio]

You can use this spray expandable foam for heaps of uses apart from it's intended use.
i.e. To build a custom air box I placed a rubbish bag on top of engine, placed tank back into position and then slowly filled rubbish bag with foam. This gave me a pretty good mould of the space I had available to use.

I had a feeling that you had already done some cool stuff with all that...

Searching your post's now to find some pics of your skills... Very cool!
I saw your 'quote' below your post... Here is one of my 'special' simpsons avartars that I use at times. You can 'borrow' it here at KB for a while if you wish friend...


Awesome people hangin out here for sure IMO!



IamCornholio

[Chrislost]

for polystyrene just get a HOT WIRE(eg short a car battery) to cut it, usually can sand a little but of smothness into that before you start to loose your balls.
My dad used it to make a plug for a RC sail boat a few years ago.

[degrom]

Yep.. the rough surface left by those balls is my problem... takes too much body filler to get it smooth again! (I've been using polystyrene).

What did you use in the end?

[imdying]

MDF


10 fuckin chars

[classic zed]

we use a commercial insulation foam for this, I carved every bit myself

it was for the power rangers

they look very different after the moulds are made and final bodywork is produced

[Thenaughtebucket]

While the style of the bike looks incredibly cheesy,looks great, the work that youve done to produce that must have been huge!

How long did it take you?