6\" horn build

Some of my mates built some foam cored fibreglass hulls for a uni project a few years ago. They used foam insulation cut to shape then coated in fibreglass. I'm not sure if or what they coated the foam with before adding resin.

I've got some samples here of foam that surf board manufacturers use. It's quite strong stuff. Also quite expensive.

Since you could only use it to form the basic shape then build the master in fibreglass on it. You might as well use something cheaper and possibly easier like wood to build the frame for your master. Wooden formers and chicken wire works...

But it's possible and worth a try if you've got an odd sheet of foam insulation around....

or a bit of clay... cheap as hell, make a layer about 1" or so thick just leave it somewhere warm for a week or two, that wont react with any chemical you chuck at it i wouldn't've thought.

worth a try as should only cost about £5 (depends where you can get clay from)

I'm sorry but....what is a chicken wire?

Chicken wire is wire netting for keeping chickens in and foxes out!

www.meshdirect.co.uk/Chicken-Wire-Netting-c-2.html

oh I get it now, but is the mould optained from a chicken wire master smooth?

Poly-ester resins also contain styrene (for the poly-ester to cross link with = better bonding), this is alsoresponsible fora, if notthestrong typical smell.

The white foam used for insulation, packages, computer housing and cleardrinking cups, is poly-styrene and it dissolves in the (normal)-styrene. Styrofoam is a trade name for poly-styrene.

Poly-urethane foam (such as PUR and 2-component foam are un-effected by styrene.
Epoxy resin doesn't dissolve poly-styrene, in paste form it's actually a verygood glue for poly-styrene and it doesn't have it's smell.

Regards

very interesting Mobiele. In your opinion could be a good idea make a master from foam coated with epoxy?

very interesting read... really like the way your project is going and its good to have friends in the fabrication area i would be interested i a few of the final product once you have it developed.


i need to build some tops so please let me know or email.

cheers
d.

b52 will do once i have them completed ill pm you

there is a type of foam specifically made for your task. its asimilar feelto blue 'styro'foam, but is a nasty orangy yellow colour. and sands easier and has less elasticity when you try and dent it with your finger. unsure of the name of it but it is made from a material that is unreacted to resin.