Quickie Q2 Lite, Construction Manual

Page: 45 / 299

shapes with ease using only simple tools. A butcher knife, old wire
brush, sandpaper, and scraps of the foam itself are the basic urethane
working tools. A vacuum cleaner is convenient to have handy since
working urethane produces a large quantity of foam dust.
..... The knife is used to rough cut the foam to size. The knife needs
to be kept reasonably sharp; a sander or file is an adequate knife
sharpener since it's a frequent task and a razor edge isn't necessary.
Coarse grit sandpaper (36 grit) glued to a board is used for rough
shaping.
..... Inside contours or "dishing" is done by using a ragged old wire
brush to rough out the bulk of the foam and following up with a scrap
foam piece to smooth the surface. The foam scrap conforms to the shape
of the surface resulting in a very smooth contour.
..... Outside contours are roughed out with a sanding block and
finished using a foam scrap. Dry micro and flox are used to fill voids
and pot fasteners in a number of places. All foam shaping should be
finished before any micro filling is done, because the filler is much
harder than the foam and this makes smooth contouring very difficult.
Your best carving template is your eyeball; an occasional check on the
depth of a contour is about the only measurement necessary.
..... Keep your shop swept reasonably well. The foam dust can
contaminate your glass cloth and your lungs. Use a dust respirator
mask while carving urethane. Try not to aggravate the better half by
leaving a green foam dust trail into the house.
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Q2 Plans - Chapter 3 - Page 3-08