RE: How to laminate flat foam????
I found that I have the solution for the finish on my boat. I have a couple of quart size "bar top" two-part epoxy kits that I bought well over ten years ago. I'm amazed that it still works as the shelf life for this stuff is under a year I believe. It does set up slowly, over a day to set and a couple of days to get hard enough to handle, but it does set up and that's what's important. I just covered the cabin/electronics cover with it as a final test. I'm con sidering laminating 3/32" balsa sheet to the bottom first though.
The bar top epoxy is working out OK. I put a 2nd coat on the cabin/electronics cover and it's pretty tough and takes spray enamel paint very well. The only problem is that it's not very thick and runs easily. It's meant to pour on, spresd and let it run down the sides and drip off. But that leaves drops of epoxy that is easily sanded off wood, but not off of foam. So, I have to trush sides and try to keep runs from happening. I did the bottom and sides and only a little formed near the top from runs. After I coat the top and top part of the sides, I may be able to sand down the raised "bubbles".
As I'm working on it during the 4th of July weekend, I decided on red, white and blue for a color scheme.