Last Thursday was our first day getting our hands dirty. Our design is becoming large foam forms to paper mache. I’m putting the forms together at home and bringing them in for the students to paper mache. The students are enjoying the process and do very well at this task. They are working well together which is good to see. These are the forms for the center of the mural. What will become the sunflower is almost 8 feet tall. We are using 2 inch polystyrene insulation board available at building supplies. I insert wood furring strips or washers in places so that our installation hardware will not tear through the foam.
The tools I use to cut and shape foam are pictured here. Knives cut foam better than saws. I tried a hot knife but wasn’t happy with it especially the smell. I use a utility knife and an old bread knife. I use a fine tooth handsaw for inserting wood. I tie the wood to the foam with rebar wire. You can use packing tape,duct tape,whatever works to attach other things together. You can make a shape out of more than one piece and join them. I often pin pieces together with dowels. Like doing drywall the form doesn’t have to be perfect but the better it is the easier it is to cover. It also needs to be structurally sturdy so no wiggly loose parts. I shape the foam with the bread knife and smooth it with a corrugated shaper. It is a messy process. I had the bad experience of having a school order the white foam made of little balls. Don’t ever get this. We had little foam balls everywhere!