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Old Apr 30, 2011, 06:45 AM
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Joined Dec 2007
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Rounding off the edges of EPP foam?

How do you guys round off the edges of your EPP foam? I'm trying different methods but I'm just making a mess.
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Old Apr 30, 2011, 07:10 AM
Space Coast USA
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Space Coast
Joined Oct 2000
21,112 Posts
Belt sander or drywall sanding screen (looks like window screen - try first with a fine grit)
Seems that it likes to be "sanded" in one direction only, if sanded in the other direction it wants to grab and rip the foam. Use light strokes at first.
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Old Apr 30, 2011, 01:07 PM
Fremont, CA
United States, CA, Fremont
Joined Jan 2009
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For large radius rounding I use a small hot-wire bow. Then sand it as described above.
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Old May 03, 2011, 12:45 AM
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Thanks, I'll try them.
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Old May 03, 2011, 02:13 AM
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Livermore, CA
Joined Sep 2004
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I use a bench-belt sander most of the time. A one direction sander also works.
If your on a budget, a drum type sandpaper roll does ok, but use finer snading grits so you don't dig in too much.
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Old May 03, 2011, 03:41 PM
flyin' fool
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Vancouver Island, Canada
Joined Jul 2003
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First shave down the edges using 45 degree slices with a new sharp blade and then drag among 80 grit sand paper in one direction only, then remove the fuzzies with a trim iron or the side of a hot glue gun tip.

The tips, stab and fuse pod were all square, then rounded using this method.
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Last edited by goldguy; May 03, 2011 at 03:49 PM.
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