foam mistakes made good

One great thing about using structural foam is that if you make a mistake while roughing out a panel, you can always make things right.  Here, you can see that I made two goof ups while shaping this panel.  1. I cut the panel too short.  2. the panel slipped out of my hand while I was cutting it on the table saw and it made a big curved gash in it. Although this was unfortunate, it is much better than making a big curved gash in your hand.

 In this example, since this is an interior panel, I'm using divinicell foam ( hence the grey color) rather than core cell foam because it does not need to be as strong.

To fix screw ups like this, all I do is cut additional foam patch pieces,. spray one side of the edge to be joined with a light mist of water from a garden sprayer, apply polyurethane glue on the mating edge, screw the patch in place and give it about 15 minutes to cure. Then lay the panel down on a flat surface and run a sanding block with 36 grit paper over the seams to knock off the excess glue that foams up between the joint. give it another 30 minutes while you work on something else and your back where you began......all ready to make another mistake.