Foam Shaping

About: I like to get creative and use materials for their not intended purpose ! Working as a refinishing technician / painter dealing with high end cars ! Lots of fun spend 90% of my time outside and or tinkering ...

Intro: Foam Shaping

 The materials needed for this industructable include th following:
- Expanding foam
- Rasps 
- Sandpaper
- A cutting tool ( knife, blade )
- Bondo 


Step 1: Adding Foam to the Form

 Take the expanding foam and apply it where you want the foam to be inorder to make your shape. Several layers may be needed. Allow each layer to dry and harden before adding another layer.

Step 2: Carving

 Use your cutting tools to shape and carve your desired shape. 

Step 3: Shaping

 Useing a rasp and diferent gritts of sandpaper you can make the surface of the foam very smooth.   Its a process that takes time and patience.

Step 4: Adding the Bondo

 Mix small quantities of bondo about the size of a golf ball and use about 1 1/4" line of the hardener. Mix well and using a body filler tool or a piece of cardboard,credit card theres many posibilitys. 
Apply to the foam trying to get even coverage. Let dry and then do some more sanding to get a smooth finish. Depending on what your going to use to cover your bondo weather it be paint or plasti dip, the surface smoothness will vary. 

Step 5: Adding Hardware

I chose to add my electronic components during the process. Tape was used to protect areas that did not need bondo. Sandpaper was use

Step 6: Applying Liquid Rubber

Using a sponge brush drip into the can of liquid rubber and apply an as even layer as you can on the bondo. Filling in gaps and dips with more rubber to achieve an overall smooth surface. Adding a second layer is recommended . Allow to dry according to the directions on the product. 

This is the final step to this process. Use this concept for many installations of various electronic and commercial prototyping

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