This is topic Q # 2 - Coating for foam in forum Old Archives at The Letterville BullBoard.


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Posted by David Otero (Member # 1645) on :
 
I plan to turn a golf cart into a giant aircraft radio. The customer has an avionics shop on a local airport. He only wanted to spice up his cart, but I convinced him that he would get some great publicity (and so would I) if he really did something fancy. What do you all use to coat polystyrene (the beaded kind) to make it smooth after carving? Due to cost that is probably the only foam I can use. Any other ideas?

Thanks in advance.
David

And yes, I'll post pictures.

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David Otero
Ace Signs
Albuquerque, NM
 

Posted by Mike Pipes (Member # 1573) on :
 
Use an epoxy resin with a thickener mixed in it.

The epoxy will not attack the polystyrene and the thickener will make the epoxy into a better filler.

I like to use the West System epoxies.. www.westsystem.com

I assume you are going to paint this "sculpture" after building it? Most epoxies, including West System, will not withstand any kind of UV exposure so they do need to be painted.

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Mike Pipes
Digital Illusion Custom Graphics
Lake Havasu City, AZ
http://www.stickerpimp.com


 

Posted by Dan Sawatzky (Member # 88) on :
 
David

I have a few questions to ask before i can really answer yours.

Are you removing the existing body of the golf cart? are you adding or building a new frame to attach the structure to?

do you have a definite idea in mind drawings ??? perhaps you could post them here or email a sketch to me. it would provide much needed information.

My biggest concern in a project like this would be durability as styrofoam without a frame doesn't take much to destroy itself with even a minor bump.

I am in the process of building s similar project right now. there is a drawing of it on my web site under the design section. the C-cab truck is already built over a golf cart chassis -actually more corectly with the golf cart running gear as we dissasembled a perfectly good golf cart and then built a frame and body out of steel and re-installed the running gear.

the trailer float is in the process of construction as follows.

I bought two wheels with spindles and welded up a small trailer. To the frame (1 1/2 " x 1 1/2 " square tubing) of the trailer I welded the float shapes of pencil rod. (1/4" round bar stock) there is a little structural steel as necessary to make it stable.

This frame will be covered with sack cloth and duct tape. yup you read right. I will have this sprayed with foam. (look up insulation installers in the yellow pages)

this i will carve and shape to give the float its final detail.

At this point you have a bunch of choices depending on the strength/finish you want. I will be using acrylic stucco with a fiberglass cloth worked into the first coat. I finish with acrylic paints.

you could also use epoxies or fiberglass finishes laid up by hand or sprayed on.

Hope this helps.

contact me if you need more info.

--dan

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Dan Sawatzky
Sawatzky's Imagination Corporation
Cultus Lake , British Columbia
dan@imaginationcorporation.ca

www.imaginationcorporation.ca www.giggleridge.com

"Isn't it great to do what you love and love what you do!"



 



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