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APPENDIX:
The Tools: (and things you’ll need)
1) Knives: a Razor knife, and an X-Acto would both be useful.
2) Glue: 3M “Insulation 78” contact cement, or Foam-Safe CA, or Elmer’s
White glue, or RC-56 type white glue, or Epoxy. You’ll probably want a
couple of these for good measure.
3) Tape: You’ll want 2” wide clear packing tape, and also some “crystal clear”
Scotch Tape if you can find it. If not, you can cut down the packing tape.
4) Sandpaper. Any Medium grit should do fine.
5) Pliers: Something suitable for wire bending.
The Techniques: You’ll probably want to practice these on a piece of the scrap
foam.
1) “Cut & Peel”
In certain areas you’ll need to peel some of the skin from the blue foam
to ensure that you get a good solid glue joint. If you don’t do this, everything
will be fine, but in case of an “impact” the skin could peel away, and you’d
have to glue it back in place (A real pain.)
Here’s how you do it. Use a SHARP razorblade, or X-Acto knife, and
run it lightly across the foam so that the tip just pierces the skin. Then, when
you’ve finished, stick the knife/razor point (or your fingernail) just under the
edge of the skin, and lift up one corner. Now carefully peel back the skin.
Do it slowly, the skin can tear when the peel reaches the little holes. It won’t
tear if you pull with small tugs held close to the foam. If you practice this will
make a lot more sense.
2) “Tapers & Angled Cuts”
a) It's almost impossible to cut a straight line freehand. So, what's your
number one tool for angled cuts? Your kitchen counter. Why not?
Formica is everybody's first choice for making hotwire templates, and
it’s tough, so use it where you find it. Lay your foam on the counter with
the end of the foam flush exactly at the edge of the counter. To
accurately control the angle of the cut, position your metal ruler on top
of the foam. If you place the straightedge directly above the counter’s
edge, you get a perfectly straight cut. If you slide the ruler back from
the edge, you get a perfect angled cut. Just make sure to get your
fingers out of the way as the hot wire or knife comes by.
b) Your other option gives you a little more time while you’re working.
Simply Cut & Peel the area where the bevel is going to be, and then
using a medium sandpaper like 200, or 250, carefully sand away the
bare foam until you have a smooth angle.
