View Full Version : Foam Hardening

08-14-2010, 01:21 PM
What is the easiet way to harden foamboard insulation. It is inside so it dosnt have to be weather proof. Does anyone have a simple 1 step process, basically paint or spray on and let dry? Looking for a simple quick and cost efffective way to just harded the stuff up a bit.


Allen H
08-14-2010, 07:24 PM
West marine supply sells a very simple two part coating that works great on foam. If mixing is an additional step then I think your out of luck. Hotwire has a coating too but I wasnt to thrilled with it personally.

08-15-2010, 01:10 PM
Hey Allen,
What is the 2 part foam coat from West Marine?
Do you have a better description or model #?


08-15-2010, 02:27 PM
Ever consider Resin and Bondo mix ?

Ive seen the 2 mixed before and makes a pretty hard surface...

08-15-2010, 04:36 PM
All kinds of new companies are always popping up offering props, masks, costumes and services to the haunt industry. This is what is needed. I have never heard of anyone being really happy with any of the coatings out there. They either don't work very well, don't hold up, or are a pain to apply.

08-16-2010, 06:04 AM
How bout Styrospray 1000, from a company out of Houston Tx....

It's self leveling so you can apply it by hand.

I know a few people have used it on foam signs and whatnot... How hard does it have to be ? What will it be used for ?

STYRO_SPRAY is made for foam...

I would highly consider a product called ARMORSTONE
Ive used this for fake rocks in the past...


Here is the 411 from the site...

ARMORSTONE is a brushable epoxy that is ideal for hard coating foam surfaces for improved durability and impact resistance. ARMORSTONE is 100% solids epoxy and will not harm or dissolve foam products. ARMORSTONE can be sanded, polished or painted with most paints.



((( I hope this helps )))

08-16-2010, 09:06 AM
Thanks for the ideas. Someone mentioned to me that they have head of using Future Floor Wax on foam to harden it up. I read up about it a little and saw that people do use it for hobbies and modeling. Has anyone used it on larger surfaces? This would be a cheap and easy way to do this if it works, just apply with a paintbrush and let dry. Anyone have experience with this method?

Allen H
08-16-2010, 09:45 AM
That will not give you a decent level of hardness, it doesnt really harden, it just puts a film on it that makes it hard to paint
With foam you trade ease of construction for surivability, the "work" of foam comes in the coating. There are lots of great things to use, they just are not cheap.

08-16-2010, 11:06 AM
I agree... I dont think your going to find a cheap ( 1 step ) answer.... im a firm believer in " You get what you pay for " I am working on a answer for you.... I am waiting for a friend from Disney to respond.... Im sure it wont be cheap, but Im sure it will be the best....

08-16-2010, 12:43 PM
Try searching for a product called Marblelite also call Styrocrete. It is sprayed on with a drywall texture hopper gun. It produces are hard weather resistant coating used on foam window surrounds , crown mouldings etc. You can also order
presprayed foam from companys similar to this one. Gingerbreadtrim.com
Check it out for ideas, and check your area for these type of companys.
They make road signs, mouldings etc. They can make just about anything you can imagine.

08-16-2010, 12:53 PM
Also check with you local fire official. Our fire marshall will not let us use any foam, hard coated or not. And as others have mentioned there is no cheap way to do it.

08-16-2010, 01:50 PM
Good point, the inspectors do not like foam used indoors. It s great for details on facades. I have found it is not much cheaper to spray it yourself compared to buying it presprayed.

08-17-2010, 12:10 PM
Depends on your application and what the scene is. In the detailing seminar at Midwest Haunters, They suggested foam masonary top coat as found at most Home Depot stores.

I used a 2 part epoxy from Demand Products that worked very well for an 18ft clown facade made of foam, but as everyone said it was not cheap. Once mixed it went on pretty easy, and I was able to tap it with a hammer and not crack it, but in addition to being close to $100 a gallon it didnt go real far.

Mike "Pogo" Hach

08-17-2010, 03:01 PM
I have a 10 by 10 clown head that seems to be coated with a epoxy, the nose has
roughed up and torn. Have you ever tried doing a patch with the epoxy?

08-18-2010, 07:49 AM
Allen, is this what you are talking about?


Will this one work?


Allen H
08-18-2010, 10:57 AM
This is what I was referring to, Polyester resin would work, but you would need to seal the foam first and thats an additional step. This stuff wont eat foam so it can be applied straight then painted.

They have alot of great stuff so dont be afraid to poke around the site and get a few things to see what you like best.

08-18-2010, 12:37 PM
I went over the entire surface of the foam with a heat gun already to texture and harden it a bit, does this count as sealing the foam?

Allen H
08-18-2010, 01:15 PM
No it doesent, the catalyst for the polyester resin eats foam like crazy, you need a layer of protection between the resin and the foam. A physical barrier like latex paint will work fine.

08-18-2010, 01:24 PM
Ok cool. One more question then I will leave you alone. Should I paint and detail them first, then put the resin on last. Or put a layer of paint on, then resin, then paint and detail them on top of the resin?
Thanks for all of the help!