Post #474273 by ZuluMagoo on Mon, Aug 3, 2009 9:40 PM

I looked around town to find various styrofoam sources and lucked out with the local Habitat for Humanity store. They had a stock of 2' by 8' foam sheets and were selling them for $2.50 per sheet. They have been used and were salvaged, so they are a little banged up and nicked, but will serve my purpose.

These are the sheets.

The sheets are 2.5 inches thick and very sturdy.

Picked up this little guy at the local craft store for $20 and worth every penny. It is a 'hot knife' and cuts thru the styrofoam like butter. Absolutely no mess, I was really woried about the little white stryo balls getting everywhere and have not found one yet.

Draw out the pattern with a Sharpie.

Start cutting out pieces.
Trick - Use a yardstick as a guide for the hot knife to cut a straight line. It does not burn the yardstick.