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Boni
02-11-2009, 02:36 AM
Can someone go through the steps involved in sculting styrofoam?

What tools do you use or need? What types of spray coatings do you use? What kind of paint?

Can a spray coat go on anything, or just styrofoam?

icandrawem2
02-12-2009, 10:02 PM
Wow this is a loaded question...Ill see if I can help..

As far as sculpting the foam (and im assuming youre talking about expanded polystyrene, the white stuff) you can used just about anything you can get your hands on. Some examples:

Hot wire
Hot knife
Electric carving knife (yes the kind you used on the turkey you burnt last thanksgiving)
Dremel, for the fine details
Grinder, either wire brush wheel or stone wheels
Dual-action sanders
Sawzall
Electric chainsaw for the big rough cuts, be careful with this one!

If you need to glue multiple pieces of this stuff together, theres quite a number of adhesives that can do this, but the best I have personally used is 3M Scotch-Weld 78. It's sold in a tank that resembles your standard propane tank on your gas grill, and it sprays out thru a gun attachment that comes separate. The adhesive bond is actually stronger than the foam itself, good stuff.

I havent had much experience with hard coating the foam, but I know its generally a 2 part urethane spray coating. (Do a search on the boards for 'spookywoods castle' and there should be plenty of information on one particular product ive been accustomed to)

Another option to coat your foam is to do it like EIFS (Google it). This involves a gypsum based compound like plaster thats applied to the foam, it will give you a sandy texture, good for brick/stone textures. Senergy is an example of an EIFS product, and it can be tinted or painted. (www.senergy.cc)

Ill let some of the other guys give you some ideas as well, good luck with it!

Oh yeah and wear a respirator when youre grinding or sanding that foam, it doesnt do much good for your lungs!

drfrightner
02-26-2009, 01:10 AM
We are going to do an article on that in the next Hauntword Magazine. So do you want me to give away all of our secrets now or save them for the magazine... LOL

One tool we use a lot is a weed eater believe it or not! That was something not mentioned before! It works quick!

Don't forget about the chainsaw you can do some quick damage with that tool!!!!

Larry

Allen H
02-26-2009, 10:48 AM
Boni,
wood rasps are excellent tools for smoothing out the styrofoam. The electric turkey carving knife also works pretty well. A Heat gun is a must have tool, you will have to play with it to learn how and what it does, but its very useful.
On the foam as a coating I use different things depending on where it will be displayed. Indoors I and out of guest contact I mix up elastomeric roof coating, joint compound, and plaster powder and spray it on through a stucco hopper. It builds up a quick thinckness that way.
On exterior surfaces (like my castle www.huntmonsters.com) I use spray on acrylic stucco. You can add a little cement to it if you would rather trowel it on, but I like to spray, even though holding a full hopper is quite a workout. If Im it on I leave the surface very rough so it gets a good mechanical bond. troweling
I have also used elmers glue and a polyfiber (a thickener from BITY mold supply) to coat foam and it works great too but takes forever to dry. Paint is up to you really as long as the foam is sealed, I normally stick to latex or acrylic as the wont react with the foam even though there may be pin holes in your barrier coat. Oil based paints will eat foam slightly and Im assuming that you know 99% of all spray paint eats styrofoam (even fleckstone) unless they are painted first with a barrier.
I like the acrylic stucco because it comes in about 30 colors, so I can normally get my base color knocked out right off of the bat. Im about to do a few big foam projects so I will try to get pics and post them.
Good luck Boni foam has lots of purposes and haunt applications.
Allen Hopps

Boni
02-27-2009, 12:24 AM
Thanks for the info. I'm and gearing up to start delving into this once it gets a little warmer, our building is not heated.

michaeldavy
05-28-2009, 04:41 PM
One of my most usefull tools is a wire brush. Different sizes remove different amounts of material . I prefer the wide ones .
http://www.michaeldavy.com/gallery/2_jaws.jpg

Just received a sample of a brush on coating that is as hard as polyures but without the spray set up. It is $54 per gal. and is available from a company called Industrial Polymers (http://www.industrialpolymers.com/contact.html)

SpookywoodsFX.com
06-01-2009, 09:35 AM
Love your work Michael.

When I sculpted the castle that Nate mentioned above, I used an electric drill with a wire brush and a heat gun. If I recall correctly, that was it.
http://i696.photobucket.com/albums/vv326/spookywoodsfx/P1010003.jpg


Tony came behind and sprayed the hard coat using the VFI-Qwik Spray System
http://www.volatilefree.com/qwik_spray_system.asp
http://i696.photobucket.com/albums/vv326/spookywoodsfx/Facade118.jpg


We had to get the paint base on it within an hour of spraying the hard coat...
http://i696.photobucket.com/albums/vv326/spookywoodsfx/P1010076.jpg


The only thing left for me to do was paint it
http://i696.photobucket.com/albums/vv326/spookywoodsfx/P1010094.jpg

SpookywoodsFX.com
06-01-2009, 09:36 AM
And PRESTO, Tony had a castle...
http://i696.photobucket.com/albums/vv326/spookywoodsfx/IMG_5424.jpg
http://i696.photobucket.com/albums/vv326/spookywoodsfx/CastleFINAL.jpg

michaeldavy
06-01-2009, 09:58 AM
were these panels mounted to plywood?
and did you coat the front and back?

Love that paint job!
And your "high lift"

SpookywoodsFX.com
06-01-2009, 10:44 AM
We only coated the front. Check out this page that Tony put together. Should answer any questions you may have.
http://www.spookywoods.com/castle.htm

The Mad Hatter
06-02-2009, 12:01 AM
Inspiration at its finest!

-Frank Balzer

SpookywoodsFX.com
06-03-2009, 08:55 PM
Thanks, I try...

freak 'n' stein
06-11-2009, 11:46 PM
And PRESTO, Tony had a castle...
http://i696.photobucket.com/albums/vv326/spookywoodsfx/IMG_5424.jpg
http://i696.photobucket.com/albums/vv326/spookywoodsfx/CastleFINAL.jpg

MOUTH. WATERING. (gaaaaaahhhh!!) Do you give tours in the off-season?! Hahaha...

twohlgemuth
06-15-2009, 01:06 AM
Mark makes it look easy, but the man has more talent in his left pinky than he lets on!

It takes a team of talented people from the carpenters on up to getting the funding in place. When it comes to making it go wow, we bring in Mark Goodson. He landed us on the front cover of Haunt World with that castle. It don't get better than that!

Well, the Gothic Church below is a really close second Mark carved out of foam free handed with no plans!

I gave a day long tour just today to a group putting a new haunt in Nashville TN. It should be every haunters duty to inspire and improve haunting for the good of the industry. As Kelly Allen would say, "Pay it Forward".

http://www.spookywoods.com/gothic/gothic.jpg

http://www.spookywoods.com/gothic/gothic2.jpg

freak 'n' stein
06-15-2009, 10:39 PM
Mark makes it look easy, but the man has more talent in his left pinky than he lets on!

It takes a team of talented people from the carpenters on up to getting the funding in place. When it comes to making it go wow, we bring in Mark Goodson. He landed us on the front cover of Haunt World with that castle. It don't get better than that!

Well, the Gothic Church below is a really close second Mark carved out of foam free handed with no plans!

I gave a day long tour just today to a group putting a new haunt in Nashville TN. It should be every haunters duty to inspire and improve haunting for the good of the industry. As Kelly Allen would say, "Pay it Forward".

http://www.spookywoods.com/gothic/gothic.jpg

http://www.spookywoods.com/gothic/gothic2.jpg

Awwww, I would've driven up there today!!! :( Please let me know when and if you ever schedule anymore!!!

HalloweenDenver
08-16-2009, 10:52 AM
icandrawem2 - nice post... covers a lot of it!

Spooky woods - very impressive!!

DarkTikiEntertainment
08-31-2009, 04:27 PM
The latest issue of Haunt World is advertising this:

http://hotwirefoamfactory.com/home.php

dshaunt
08-31-2009, 08:02 PM
http://i696.photobucket.com/albums/vv326/spookywoodsfx/CastleFINAL.jpg

Thats just not fair.

SpookywoodsFX.com
04-20-2010, 07:50 PM
HotWire tools are a must have. You 'could' get by without them but the more tools you have on your belt, the better. There is allot you can do with the hot wires that you just cant otherwise. Definitely a good investment!



The latest issue of Haunt World is advertising this:

http://hotwirefoamfactory.com/home.php

harrishaven
04-23-2010, 02:13 PM
Posted few pics of the styrofoam pillars we build outside our haunt

www.harrishaven.com

they look pretty close to real

SpookywoodsFX.com
04-27-2010, 11:31 PM
Damn right, great job! How did you go about making them?


Posted few pics of the styrofoam pillars we build outside our haunt

www.harrishaven.com

they look pretty close to real

harrishaven
04-28-2010, 11:44 PM
First we made concrete forms for them to sit on and to attach our 2x4 wood plates to. Then we made our column structures and skinned them with plywood. Next we cut 1/2 inch thick extruded pink foam to fit cutting it so the corners are at 45 degrees screwed them in place and drew the mortar lines so all sides matched. we labeled them when we removed them so we knew what side they went on after we used a router with a 1 " bit to carve the lines. Then we put them back up with glue and some screws and used caulk to seal the edges. Then I took lacquer thinner and threw it on to age the brick. next we painted them with grey primer then with black exterior paint. then painted in the grout lines. Finally we used sea sponges to put on the brick dust paint. they turned out great. will post more pics closer up and will post pics of the creamation oven I am working on.