Post #493237 by MadDogMike on Wed, Nov 11, 2009 9:13 AM

surfshack, welcome to TC. Looks like you've got some good suggestions here to start. I've played with foam some so here's my 2 cents worth:

You can start with a sheet of 1 inch foam on plywood, then add irregular shaped pieces of 2 inch foam to get the 3D effect

White glue can be problematic when laminating large sheets of foam since air doesn't reach the center and the glue doesn't dry. I use Gorilla Glue, it uses moisture to cure the glue. You mist the foam lightly with water before you glue it, "damp it and clamp it" they say. I also use short pieces of bamboo skewers or toothpicks to pin the foam in place while the glue sets, if you push the skewers in flush with the surface of the foam you can just leave them there. Be sure to use gloves and drop cloths when working with Gorilla Glue, it doesn't wash off - EVER!

There are some commercially available coatings like Vanillacryl or "Steve's Coating for Styrofoam" but I haven't tried them because they are expensive and I am cheap :) You can mix up "Monster Mud" to coat foam with. 4 parts premixed wallboard compound and 1 part latex paint. Mix well and apply to the foam. I have also mixed small gravel in with the Monster Mud to add texture. After it dries, paint it well with latex paint. You can't use spray paint on foam because it eats the foam, but after a good coat of Monster Mud and latex paint, you can use spray paint for an "airbrush effect" for shadows and highlights. All of my foam projects have been temporary, I can't say how Monster Mud would hold up for a permanent project.

You best bet is to experiment with a small section before you build a huge wall. Here are some samples of my foam work in case you get bored :D