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Creating Large Styrofoam Mini Shape
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Author:  phillb [ Sun Mar 30, 2014 10:17 am ]
Post subject:  Creating Large Styrofoam Mini Shape
Hi All,

My Daughter is doing a HSC textiles protect which will be a mini made of fabric. We are hoping to create of carve the shape of a classic mini in foam which will act as the structure under the fabric.

She could carve the mini out of a large block of foam or perhaps Cad Cam would be an option (although I imagine an expensive one.)

Can anyone suggest where in Sydney we can buy large blocks of foam. The mini will be about 90cm long so we need a big block, or glue smaller blocks.

Below is the roof which is a union jack. I might even start a build thread!!

Image
Author:  Harley [ Sun Mar 30, 2014 10:54 am ]
Post subject:  Re: Creating Large Styrofoam Mini Shape
To get it cad / cam machined would be very expensive. Could be a couple of thousand!
My quote was $1000 to get a dash carved out!

Full detail of a machined one would be useless under fabric anyway.
Just buy a bunch of blocks and car e it by hand i reckon!
Author:  Thorlek [ Sun Mar 30, 2014 12:51 pm ]
Post subject:  Re: Creating Large Styrofoam Mini Shape
people who build model aeroplanes often use CAD / 3D routers / laser cutters to carve wings out of foam.

you could try emailing your local model aeroplane club to see if anyone in the club can do it... or at least source the foam for you
Author:  simon k [ Sun Mar 30, 2014 1:34 pm ]
Post subject:  Re: Creating Large Styrofoam Mini Shape
Thorlek wrote:
people who build model aeroplanes often use CAD / 3D routers / laser cutters to carve wings out of foam.

you could try emailing your local model aeroplane club to see if anyone in the club can do it... or at least source the foam for you


yeah, a bloke I know made one.... easy enough to do, but involved.

Google "hot wire styrofoam cutter" - there are plenty of examples of how to make one
Author:  Mick [ Sun Mar 30, 2014 1:55 pm ]
Post subject:  Re: Creating Large Styrofoam Mini Shape
I've seen large truckloads of styrofoam around construction, I suspect it may be utilised in wall insulation these days.

I would try plasterers or similar to find their source.
Author:  MG Rocket [ Sun Mar 30, 2014 2:38 pm ]
Post subject:  Re: Creating Large Styrofoam Mini Shape
Mick wrote:
I've seen large truckloads of styrofoam around construction, I suspect it may be utilised in wall insulation these days.

I would try plasterers or similar to find their source.

Probably waffle pods, used instead of sand fill for foundations. I'm no fan of the idea.
Author:  winabbey [ Sun Mar 30, 2014 2:43 pm ]
Post subject:  Re: Creating Large Styrofoam Mini Shape
Phill,

How about building the rough shape of the car with cardboard boxes or similar, then spray all over with some of that expanding foam you can buy in a pressure pack can at Bunnings, etc. ?
It works a treat at filling voids around floors and cupboards. Wear some disposable gloves so you can mould it to a rough shape around the boxes initially. Then, once dry, use a serrated knife to trim to shape.
Author:  Phil 850 [ Sun Mar 30, 2014 5:48 pm ]
Post subject:  Re: Creating Large Styrofoam Mini Shape
I bought High Density Styrofoam sheet from Clark Rubber.
Its available in many thicknesses up to 100mm.
I used it to make up wheel arch flares and a flip front for a mini.

Phil
Author:  Bubbacluby [ Sun Mar 30, 2014 6:11 pm ]
Post subject:  Re: Creating Large Styrofoam Mini Shape
Ausmini Flugtag?????

Where did chop chop source the Styrofoam that that mini was made from?
Author:  womble99 [ Sun Mar 30, 2014 6:41 pm ]
Post subject:  Re: Creating Large Styrofoam Mini Shape
phillb wrote:
Hi All,


Can anyone suggest where in Sydney we can buy large blocks of foam. The mini will be about 90cm long so we need a big block, or glue smaller blocks.


Phill,

you could try these guys for foam blocks http://www.polyfoam.com.au/index.php or http://www.justfoam.com.au/# they are in Sydney and look as though they might be able to help.

If you were in Adelaide I could have just grabbed a block on my way to work.....

cheers,

CJ
Author:  69k1100 [ Sun Mar 30, 2014 7:16 pm ]
Post subject:  Re: Creating Large Styrofoam Mini Shape
Be aware though there are hundreds of different types of foam. Polystyrene is the most common, and one of the cheapest, but the closed cell type is made of little balls and pretty hard to carve down to a really smoth surface as it tends to "chunk". The blue open cell type lends itself to carving better but is harder to cut with a hot wire due to the increased density.

Urethane foams are by far the best for carving but will not be able to be cut with a hot wire (think green florists foam) and you get a lot of particulate in the air. You can also spray urethane foam with solvents (high build primer/spray putty)

90 cm is quite big, have you researched any premade shells for rc cars?
Author:  phillb [ Sun Mar 30, 2014 8:08 pm ]
Post subject:  Re: Creating Large Styrofoam Mini Shape
Thanks everyone for the suggestions and the PM's. Thats given me a few leads to work on. I'll see how i go.

Phill
Author:  drmini in aust [ Sun Mar 30, 2014 8:15 pm ]
Post subject:  Re: Creating Large Styrofoam Mini Shape
You could make a cardboard or ply?? mould and mix up some poly foam- http://www.biasboating.com.au/Foaming_Resins_s/402.htm
Used to foam underfloor of boats.
I'm not sure how hard it is when reaction is complete....
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