I've been sculpting PU foam for my new car. I glued together 4 blocks at the right angle to give a slight compound curve for the lower side of the car. I drew a long line across the top with the right curve and started to cut and sand the foam. Even though I took a lot of care and measured where possible, the result is a disaster The problem is that once a lot of the foam is trimmed away, there's nothing to measure from. Where the foam gets very thin (two blocks back to back and cutting through the join at an angle) the thin edges just stick out.

How have other people made their foam cut to the right shape?

Look at the master at works archive for this:

Fred W B

Build a frame from ply and infill, look for the body photo's

[Edited on 28/8/08 by mark chandler]

quote:

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Originally posted by mark chandler
Look at the master at works archive for this:

Fred W B

Build a frame from ply and infill, look for the body photo's

[Edited on 28/8/08 by mark chandler]

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Yeah, I've read this thread with some awe. I want to get mine done this year if possible, certainly this decade. Fred's car will be a level of excellence higher than I need to achieve.

u2u sent matey

Hi guys, thanks for kind words

Smart, I would agree that shaping just foam is difficult. What was nice about having my ply ribs is that they give you hard reference points when shaving off the foam.

I'n not quite sure what you are doing but to get a shape consistent or to match something I would suggest cutting female templates in ply or hardboard to compare the shape you want to the foam as you work it off

Cheers

Fred W B

Female template being used in 5th picture down. Different kind of foam, but the idea is sound.

http://bbs.zuwharrie.com/content/topic,86455.0.html