Styrofoam Letters

[andyb]

This is for everyone that wants to or has asked about cutting Styrofoam. I have a customer that wanted me to cut several letters for him in 2" Styrofoam. Here is a test letter that I cut before I started cutting his sheets. The letters came out great and the edges very smooth. I couldn't have been happier.

I used a 1/4" Super-O up-spiral, conventional cut, move speed was 3 ips and the RPMs was 14000.

Andy B.

[blackhawk]

Andy - Do you have the brand and part number of the bit that you used?

[joe]

Good post Andy,

Now the job begins. For interior or exterior use it takes longer to paint or texture than anything else.

It's been a long time since I've made this product. So what's the best hardcoat? I know plain old latex isn't the best.

Joe Crumley
www.normansignco.com

[twelchPTM]

I don't know anything about these product but in our shop we have a gallon each of styro-prime and styro-coat. I also have seen but not used a product called shell-shock. alot of the surrounds for our water-play area are coated with the shell shock

[twelchPTM]

another thought, rubber dip(aka plasti-dip) can be sprayed and produces a flexible and durable coating on almost any substrate and can be purchased in clear with a pack of tints to create custom colors

[billp]

Thomas,
While Plasti dip might work on a number of materials, their safety sheet makes it appear to be solvent based - http://www.plastidip.com/docs/Plasti...0oz%20MSDS.pdf ,and that would mean you can't use it on styrofoam (unless you are looking to achieve special effects...)
We've seen some very nice work ( see Terry Jones pix on the Camp blogs from both Houston, and Austin,TX) with the combo of styrofoam, and Durham's rock hard water putty as a top coat- http://www.waterputty.com/ , and for people looking to try styrofoam it would be a great starting point.
Joe will probably chime in soon and give you his opinion on the Styro family of coatings...

[joe]

Bill,

As you know, I'm fond of Durhams Rockhard Putty but it's one downfall is how brittle it is. I would encourage anyone to try it on EPS foam knowing the first hail stone will open up a hole.

The cheapest and best I've found is the concrete texture coating by Sherwin Williams. It only comes in 5gal tubs at $150.00. Any coating for eps foam takes lots of time to apply. That's the expense.

Joe Crumley
www.normansignco.com

[mjindustry]

Any coating for eps foam takes lots of time to apply. That's the expense.

The road that inevitably leads back to HDU for us. Everytime, without fail.

[joe]

That's right. It's sometimes easy to loose money while trying to save it.

I know there's a case to be made for eps and beadboard foam. That's one I haven't been able to make. Here's the point! HDU is cheaper for making letters than beadboard when you figure the coat out time. But even better is 1" PVC. It's toughter than just about anything on the market. At $150. a sheet it's a bargain.

Lets say your making 12" letters. From a 4X8 sheet the cost per letter is approx. $5.00 per letter. Jees, how do you beat that.

Another advantage of PVC is, you can throw one a letters across the room and it won't break. Run over it with your truck, wont break.

There are two down sides. First off it's heavy. Second it doesn't sand well. But it paints well with just about anything. No need to paint if you it white but will accept any kind of coating. Even Latex.

Joe Crumley
www.normansignco.com

[joe]

There should be a permanent Topic Heading, "Sign Myth Busters."
Here are a few Myths to be exposed


HDU doesn't expand or shrink. It's dimensionally stable.
3D signs are the best way to make lots of money.
Screws are a good attachments with HDU.
Gorilla glue is stronger than most adhesives. I swear on it.
Epoxy works perfect when spraying.
Wood is a second quality exterior sign product. That stuff rots, cracks and won't hold paint!
A vacuum hold-down is essential.
Aluminum routing needs a mister.
You need a 3D program to go into business.
Learning to use a brush isn't profitable or fun. It's agony in the making.

I could go on for ever.

O, I forgot a few,

Home Owner Associations are good business.
There's lots of money to be made in Pin Striping.
Installations are a breeze with Dr. Crumley's Instant Post Holes. Guaranteed!

Joe Crumley
www.normansignco.com