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Author Topic: How to cut and shape soft foam  (Read 21203 times)
maduncle
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@maduncle
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« on: April 15, 2011, 05:28:03 am »

Hi there all,

I thought this might be worth passing on to you all.

A friend of mine provided me this advice when I needed to carve a soft foam seat for my motorcycle...

HOW TO CUT CARVE AND SHAPE SOFT FOAM.

1/. Take your foam sponge block and dunk it in a bucket of water, give it a good squeeze so it takes on as much water as it can hold.

2/. Put it on a piece of baking paper, put it on a tray and put it in the freezer.

3/. Take it out once frozen and begin carving. It will respond to serrated knives, rasps, sandpaper, etc - just like hard foam!

Once you are done, leave it to thaw out and you will have your sculpted foam shape, all smooth and free of knife marks.

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bicyclebuilder
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A.K.A. Scanner Camera Builder


« Reply #1 on: April 15, 2011, 07:45:29 am »

Great advice!
Although I use firmer, rubbery foam for bike seats. Soft foam doesn't seem to give enough resistence to my touchy. With the rubbery foam, you can just cut, rasp and sand without freezing. When I want to make the seat more spungy and luxurious, I cover the rubbery foam with a sheet layer of soft foam.
I've also found out thrugh trail and error that you need to smoothen all the bumps and edges before covering it with leather/pleather or else you get a lumpy seat.
Again, great advice.
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sidecar_jon
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« Reply #2 on: April 15, 2011, 10:15:56 am »

sounds interesting, most foam suppliers i've dealt with, seem to use an electric carving knife...or a hot wire.
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Mr. Boltneck
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United States United States


« Reply #3 on: April 15, 2011, 07:15:02 pm »

Interesting. Definitely a method to remember. Thank you for passing that along!
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Ravenson
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« Reply #4 on: May 31, 2011, 08:20:20 pm »

When I worked in the O&P lab we used a electric stand drum  sander on soft foam all the time.  You just have to take you time and be careful to make sure you do not remove too much too fast.

Jeff
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Lilthuglet
Swab

United Kingdom United Kingdom


« Reply #5 on: June 02, 2011, 10:24:27 am »

Another method a friend of mine recommended for the more dense foams is a soldering iron. Thought I'd pop it up in case it was of use to anyone.  Smiley
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lilibat
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« Reply #6 on: June 02, 2011, 10:41:26 am »

Best thing I have found for cutting foam is an electric carving knife.
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Otto Von Pifka
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« Reply #7 on: June 07, 2011, 08:52:03 am »

thank you sir! the missing piece to the puzzle!

reading it, it sounds so obvious!

thank you for sharing!

I have a half dozen projects in limbo and this should get the ball rolling again.
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K.Betteridge
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Netherlands Netherlands



« Reply #8 on: June 10, 2011, 11:32:49 pm »

This sounds easy and simple, but I do want to ask if you have a picture of the end result of something you made this way. Curious on how it will turn out.
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Flightless Phoenix
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« Reply #9 on: July 25, 2011, 02:45:44 pm »

Very useful tip- thanks for posting!
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