Building Plugs with Foam
I have received many questions regarding the foam that I use in my building projects. So many people immediately think that the polyester resin (the cheap stuff) attacks the foam that I use.
Since I use dry floral foam blocks with my small hobby projects, this is not an issue. The problem that most people have with resin attacking foam is the case where polyester resin attacks Styrofoam.
Styrofoam comes in sheets from the local hardware store and is very cheap and very easy to shape. Styrofoam can be easily shaped with keyhole saws, jigsaws, reciprocating saws, serrated knifes, band saws and saber saws.
Styrofoam, however, has a major drawback of being attacked by your polyester resin. The easy answer to this problem is to use epoxy resin over Styrofoam. The problem with epoxy resins lies in their costs. If you are working on a large project, epoxy resin can get very expensive.
That being said, there is yet another easy and inexpensive solution to the problem of using polyester based resin materials over Styrofoam. This solution involves painting the surface of your already shaped Styrofoam with regular old acrylic house paint. The resin does not adhere easily to glossy surfaces so the paint should be sprayed onto the foam.
Remember that this paint is intended for brushing or rolling and will therefore be a little too thick to spray as it is. You will have to thin it with a little water. For the best coverage of the foam you should spray on three layers with adequate drying time between each layer. I would also recommend using a different color of paint then the foam you are painting for obvious reasons.
Once the paint has dried, you’re the surface of your plug can safely be coated with Bondo, polyester resin and of course epoxy without fear of being attacked.
I hope that this clears up some questions and concerns regarding plug materials. Styrofoam is a great plug material as it can be carved to shape your surface and it acts as filler material at the same time.
Happy Building
More coming soon…
Steve
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After the PVA dries, I brush in a nice healthy layer of gelcoat. Once the gelcoat cures to a tack, I begin to lay resin and mat. Since this is a fairly large item, I do two layers of 1 ½ ounce mat to provide a little strength without the part getting too heavy.
makes a huge mess if it gets on something other than your project. I lay down a nice thick layer of gelcoat making sure to get good coverage around the base where the plug meets the board.
Spending time at this stage pays off in the end. Like I always say, every flaw that you are too lazy to work out of the plug at this point will become a flaw that will have to be worked out on every piece you ever make with the final mold. 



I also use a ruler and check the basic measurements of buck stations that I consider critical to the final outcome. These don’t have to be perfect, but it should be pretty close, more symmetry at this point will insure a greater ease of building this model in the later stages. Once I am comfortable with the symmetry, I can move on and start filling the two halves with dry floral foam 