Foam Source
 

Hello,
I've been flying RC for about 17 years now and I am trying to get into scratch building with foam. I built myself a foam cutter and it works great ! My cutting thus far is limited to old coolers, styro cups, etc. My first project is to build a new wing for an old sweet stick that has been in the attic for 10 years.

Is there a good source for EPS foam? (Is there a better foam to use for 40 + sized aircraft? I intend to sheet with balsa. I can't seem to find foam block in my area, but if anyone knows of retailers that sell it (or websites to order it), I would be most grateful!

Thank you!!
Robert

RE: Foam Source
 

Some building supply stores have it. Menards, Lowes, Home Depot. About the thickest they have is 2". Another source worth looking into is commercial builders. Some use thick billets of foam as the outside decoration on stores, condos, etc. They stucco over it and then paint it. That's where I found my last chunks--2'x1'x4'. A local restaurant was up-dating its front and the builder used foam and I got some leftover pieces. Regards.

RE: Foam Source
 

Go to the yellow pages...on the Internet look under plastics then narrow it down to foam. You may also try Thomas Register on the Internet. I would guess that you are looking for 1 lb. per cubic foot white foam....styrofoam.

There are plastic suppliers in nearly every part of the country and they have hot wire cutters to size the foam to the thickness that you need. They get the foam in huge billets or make the billets themselves. Then they cut it down to size required. These companies may be in the business of making architectural products, insulation, foam for boat docks, etc. Foam supplying is a huge huge business. So you shouldn't have any problem getting the foam.

Buying from a building supply company is NOT the way to go....unless they have what you want in stock. Shipping charges are AWFUL. You need to find a supplier where you can drive there and pickup what you need.

For example, I recently bought a stock of foam from http://www.gafoam.com/ It is a huge foam company with plants near Atlanta and another up on the East Coast. Look at it for reference...then go looking for similar companies in your part of the country.

Cheers,

Ken Blackwell

RE: Foam Source
 

I buy my foam from Home Depot, because I know their source. Most foam manufacturers will have a minimum invoice amount.

The big drawback to building supply stores is that you do not always know what you are getting. For our use we need 1 lb. density, virgin ESP foam. Some of the ESP foam is not virgin foam and has recycled foam in it. This is fine for insulation but not so good for us. Recycled foam will have hard beads in it. When cutting, the wire will hang up on these beads and dwell for a while. The result is ridges along the core. You do not get this with virgin Foam.

Ed S

RE: Foam Source
 

The local foam mfr for me, Imperial Foam on Rt 40 outside Ormond Beach. FL will sell you whatever quantity you need at a reasonable price. Not just sheets, but also CNC wire cut shapes. I've used them for other non-aircraft shapes, but if I gave root & tip airfoils on CAD, plus a wing layout, they'd even cut wings for me.

This from a place that expands it's own styrene beads and cuts the blocks into slabs for industial use and vairied shapes like fake columns for architectural decoration.

RE: Foam Source
 

Thank you for all the replies!

The gafoam place may be an excellent choice for me (I live in the ATL Area). I have had trouble finding the 2" by 4' by 8' sheets at the Home Depot. All that is stocked around here is the 3/4". I've also checked Lowes and a few other building supply stores.

Thanks again all!