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Unread 09-24-2012, 05:46 AM   #1
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Need ideas to cover Craft Foam (Foamies)

So Im making a extremely large sword and need it to be as light but durable. So Im making it out of sheets of craft foam. I personally prefer craft foam over shaping pink/styrofoam.
I need some help with thinking of ideas to cover the craft foam, since there are breaks where two sheets of foam meet.

I have used fiberglass resin over craft foam and it doesnt melt at all BUT it takes A LOT of coats and if you press on it, it will crack. With fiberglass cloth helps but it makes it extremely heavy. Same goes with bondo...

Does anyone have any other ideas I can cover craft foam with to cover breaks and able to spray paint it?
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Unread 09-24-2012, 11:29 PM   #2
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Have you tried using crayola model magic? That's what my cousin used to cover the cracks/breaks when she was making her princess bubblegum crown with craft foam. It's not too expensive and is light weight.
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Unread 09-24-2012, 11:38 PM   #3
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Start with paper mache. Then move to something like gesso or another thing like that. Then if you want to use the fiberglass over that, then you can..
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Unread 09-26-2012, 04:40 PM   #4
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I've used craft foam for larger pieces and just used wood glue in several coats to seal it for painting. I'm not sure it would hide the seam though, I've always been able to use one long piece.
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Unread 09-26-2012, 04:46 PM   #5
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I'd like to suggest Mod Podge. Cover the seams in cellophane tape but don't push it in to the cracks. Mind the edges. cut them so they don't have that rough thing going. Give it about six coats and then wet sand it perfectly smooth. Repeat as necessary.

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Unread 09-26-2012, 05:31 PM   #6
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I suggest using a sealer. I usually mix glue and water together and it works perfectly! I always use this method for making detailed armors. Use one part elmers glue, one part fabric glue and two parts water. Put on a few coats and it'll make the foam really smooth.
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