Later that same day....
I hope the mods forgive me for not just editing it in, but significant bits have been added... that and if there's a text limit I'll probably meet it.
Work was canceled today, so I started testing this idea I had, I'm going to call it the "icecream Bar method".... because it looks like an Icecream bar. It seems like it would be a nice light weight way of making swords as well... or anything with beveled edges :P
Anywho getting started.... Yah big pictures I know.... I didn't feel like resizing, I just shifted the camera down to 1 megapixel(that's as low as it would go) sorry. Edit: Thankfully Photobucket resized them all. LOL
I guess I should start with my shopping list.
1/3 sheet of pink insulation foam(left over from other projects, managed to get 2/3rds of the thing out of it.)
1 wonder cutter. (Already had. Live by the foam cutter, die by the foam cutter)
1 packing tape (already had)
3x black posterboard(they didn't have white, only used 1.5 anyway) $1.80
1x Double sided tape $1.92
1x disposable box cutter with breakaway blade $1.54
1x Elmer's stainable woodglue $2.94
So just under 10 bucks so Far.
Anywho, I cut out the template I made earlier. Then used it to measure and cut
all the posterboard I would need. 12x center piece. and only one top, bottom, and side piece
since I could just pull them off and stick them on the next piece.
After all that was done It was time to cut the foam. I got out the old slide droor for my keyboard that I refused to use to use as a streight edge
. In theory it should have been streight since the blade was flat against the board, but I guess the blade flexed a tiny bit. Not important. Anywho, I cut like this
, and it went pretty quickly.
Next was to make some sandwiches. get some glue close to the edges
, then well.. make a sandwich.
Note that I kept a napkin around to wipe off any excess glue. You don't want blobs of glue on the edge because it takes time for the foam cutter to get through that. It's REALLY slow. Finally... Lay some stuff on it to Keep it flat
. Otherwise it's going to want to curl a bit. When it dries though it will be rigid and streight and have next to no flex.
Now... Sit down wait for them to dry, and have some Ice Cream Sandwiches
. The next part is really long and involved, so to keep you from being bored, here's a cat with a dirty sheet on it
. EDIT: That really does say "COOK" as in kiss the cook.
Moving along... Remember all those little top, bottom, and side pieces you cut earlier? Now it's time to pull them out. I started with putting on the bottom. Make sure you use the pattern you cut out earlier, and line it up with the posterboard in the middle
. The foam edges aren't always streight so if you just try to center the bottom, your angles will be off.
Now here is the magic of these two pices of posterboard. The foam cutter won't easily cut through them, so they act as guides. with the guides set you can just ride your foam cutter down them to get a nice accurate angle
. This is why I think it would be incredible for making swords or beveled edged weapons.
Anywho, moving on to the top... I put on the side piece and the top piece, and just like the bottom, carved it out
. The double sided tape I bought seemed to still be sticky, so I just peeled it off and stuck the side piece to the other side and cut away. (The tape actually lasted through all 4 pieces)
when I was done I pulled off all the pieces of posterboard I'd taped on, and the result was this: A 3-d copy of my template
Now this is time consuming because the foam cutter moves SLOW. I should probably underscore that but I'm lazy. I finished the next four pieces in about an hour.
Afterwords I Grabbed all 4 and taped them together
on the inside with some packing tape just to see how it would look untill I got them all cut and glued them together.
So that's where I'm at now. I'm out of insulation foam with 4 more pannels that need to be cut. Hopefully I'll manage to stop by and pick them up this weekend. Otherwise all that's left is some sanding(to knock those beveled edges on the top down to make it look round)