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I need to make a quarter circle on a 5" diameter out of 1/8" dense foam core sheet 2 1/2" high.  

 

I'm thinking some sort of pipe or bottle for a form, a hair drier or similar heat source, and some way to hold the foam core until it hardens up again.

 

Has anyone done something similar and am even close to being on the right track?

 

Any comments and / or suggestions will be appreciated.

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You won't be able to bend foam core by heating it.  The problem is the paper that sandwiches the foam.  You will have to make a series of closely-spaced slits along the length of the concave side of your desired curve. You should then be able to form the curve, but I doubt that the foam will hold the curve, even if you heat it. You will need some way to set the shape.  Perhaps hot-glue or epoxy?

Well, after destroying a lot of foam core I gave up, bought a sheet of styrene, and did what I should have done in the first place.  I cut a piece  bit over-sized, heated it with a hair drier, wrapped it around a glass jar of the right size while keeping the heat on it, and put four pieces of thin card stock over it and rubber banded the whole thing together.

 

First try was pretty good, second try was dead on..... except I should have cut the window openings first.

 

Back to the bench.

Well, after destroying a lot of foam core I gave up, bought a sheet of styrene, and did what I should have done in the first place.  I cut a piece  bit over-sized, heated it with a hair drier, wrapped it around a glass jar of the right size while keeping the heat on it, and put four pieces of thin card stock over it and rubber banded the whole thing together.

 

First try was pretty good, second try was dead on..... except I should have cut the window openings first.

 

Back to the bench.

another method of making curved wals is to use the same layers of cardboard you used to protect the plastic simply wrap the bottle or form which is the desired radius with thin cardstock ( grey chip board works great) and laminate several sheets around the form with a coating of glue between each layer. let it dry and you have a solid well shaped and stable wall..

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