Post cutting, sheathing over foam mold questions

[bahed]

I am thinking about jazzing up a go-cart my kids and I are making. I have designed and cut to shape (out of the blue foam insulation boards found at the Home Depot type places) a nice couple of forms. I am wanting to use these forms as molds to then put a hard material overtop. Not talking titanium tough. Not a safety part - except maybe to keep the bugs down!

Is there any reasonable approach (can be done by a guy with typical tools), without spending a bunch of money. Looking for something a bit flexible, not fragile. Something like plastic. I just wasn't sure if something like plastic can be readily applied. It would be nice if it could be sanded and painted. The only thing that comes to mind is fiberglass impregnated bondo.

Is there anything else out there that you folks have had success with ?

Thanks

[Ger21]

Cover it with fiberglass cloth and epoxy. That's a very common method of making composite parts. You can't use fiberglass (polyester) resin, as it will melt the foam, so you have to use epoxy.

[bleeth]

Forget Bondo-It is polyester based and will eat that foam. Epoxy based as Gerry suggests is a good way to go. You can mix Epoxy with cotton or wood fibers (Available from West, System 3, and likely others) that will make a good hard-coat. Best is to use some fiberglass cloth as Gerry says and then spread and sand epoxy mixed with fibers to end up with it smooth for painting.

[feinddj]

It depends on how much "not a lot of money" is to you. There is a plastic coat compound called Sculptocoat which can be found at theatrical suppliers. We use it to give a nice surface to white foam carvings that is durable.

If you are on the East Coast there is a company in West Virginia that makes Jaxsan. It is a roofing paint that is almost identical to Sculptocoat. If you need a bit more durability, nylon screen wire laid into wet and then coat again. I used this method to make stage platforms out of white bead styrofoam that had to be walked on, by actresses, in heels.

David