Post #475622 by ZuluMagoo on Sat, Aug 8, 2009 3:37 PM

Have started putting the puzzle together. Started out cutting a small bamboo pole and using the pieces as nails to hold it together.

You can't use regular gule or adhesives with polystyrene styrofoam, they will not bond and will melt the styro. So I tried several different glues including Gorilla glue and a special styrofoam glue from the hobby store. They didn't work that well, and they were going to get very expensive for the amount I needed. So I ended up using 'Great Stuff'. This stuff is REALLY EASY to use. You can get a can for less than $4 at Home Depot.

Notice the warning right on top of the can? Pay attention and wear gloves!! I did not for the first several days and this stuff is a serious bitch to clean off your hands! Goo Gone, nail polish remover, lava soap, none of it works. Just spray it on and use like a mortar between the pieces. As it sets it expands and bubbles. After a little experimenting, you will get used to how much to use.

This guy stands about 5 1/2 feet tall. Once on the stand, it will only be a few inches from the ceiling of the Kona Luanii.

After I have the frame assembeled, I needed to cover the surface with something to give it some texture before painting. Originally, I planned to cover with a skim coat of stucco (with sand in the mix) to give a rock texture like finish. However, after working with the Great Stuff, and making some mess, I discovered it also works great as a surface texture. When you spray it, it comes out of the can as a light airy foam.

Put I just took a scrap piece of styrofoam and started spreading it around like icing a cake.

(Note the gloves, this is when it can get pretty messy)

When the Great Stuuf dries, it gets rigid like a hard shell over the styrofoam but is still incredibly lightweight. The texture starts to look pretty cool, like rock or lava.

At this point, I have about 20 hrs. into this guy.

The great thing working with styro is the weight. Right now he only weighs in at about 12 pounds.

Still need to attach the ears and then start the painting.