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  1. #1
    Senior Member Frost's Avatar
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    Source for high density foam, and shaping ideas?

    I'm in need of a block of high density foam. The sort I'm talking about would be found on the handles of some trekking poles, some foam sleeping pads, the foam block style car-top kayak carriers, etc.

    Its for a DIY trekking pole project I think you guys are going to love.

    I'd also be interested in advice on how to shape the stuff effectively.

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  2. #2
    Acer's Avatar
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    Most of your whitewater kayaking shops or suppliers carry different kinds of high density foam for knee padding and filling in the front of your whitewater kayak to thrust your feet against...here is NRS's web site for example showing different types of HD foam as well as fill - in foam. and glue,

    http://www.nrsweb.com/shop/product_list.asp?deptid=1764

    You can pretty much mold the stuff any way you want it or shape it even.

  3. #3
    Acer's Avatar
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    You might also consider cork,,,as you can get that from any fishing rod building supply place. comes in sections,,glue it to handles and sand it down.

  4. #4
    Prefers life at 12 MPH. FLRider's Avatar
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    Are you looking for Neoprene foam? If so, Rockywoods sells it, including a sample set of all of their colors and thicknesses for $25. Outdoor Wilderness Fabrics also sells neoprene (go to "Notions", and a sub-menu with the neoprene option on it will pop up).

    I'm not sure if you can use an hot knife to cut it, but I wouldn't be surprised if you can (that's the recommended way to cut most foams, including the blue CCF pads, craft foam, and the wall insulation stuff). If you do try to use an hot knife, do it outside; the vapors released by cutting foam that way are particularly nasty.

    If you're looking for other kinds of foam, DIY Gear Supply sells 1/4" thick "microcell foam" that's the kind usually used in shoulder straps and waist belts by the inch.

    Wallyworld (and several craft stores) carry various kinds of craft foam that may work for what you want. And, of course, there's always the ubiquitous blue camping pad to cut up (those definitely can be cut with an hot knife).

    Hope it helps!

  5. #5
    Senior Member Frost's Avatar
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    Acer, thanks for the link. It looks like they've got a block that will work perfectly and is pretty inexpensive compared to my locally available options.

    I considered cork, and may still try it, but to get highly contoured, uniform shapes, it looks like a wood lathe is almost a necessity.

    FLRider, This isn't neoprene, it's much firmer than that, but it feels 'softer' than the cheapest walmart blue pad. Gossamer Gear's pad, as well as some of the better blue pads you can find at Gander Mountain or ****'s Sports are made of the stuff I'm gunning for. I'm trying to work from a single block rather than layers of thinner material glued together, or a 'wrap' that's glued down because the glue makes very noticeable seams in foam that made for a rather unpleasant handling in my experiments. I'm going to need a block at least 3" thick, but 4" would be better.

    I might just see if I can track down a block of memory foam to work with instead, but I'd have to come up with a means of putting on a fairly tight, durable fabric cover if I go that route.

    If - if he stood! Enough of ifs!
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  6. #6
    Yoda's Avatar
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    If it is minicell foam you are looking for???? I did a little google foo and found this for you:

    http://www.kayakproshop.com/minicell.html

    http://www.huki.com/store/index.php?...index&cPath=20

    There were a bunch more listings but I choose these two, you could browse the others if you feel so inclined.
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  7. #7
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    I did something similar on the cheap by laminating squares of a ccf pad into a block and then shaping it. It worked OK and it looked nice with the laminations in there. You could do a first round cheap and go from there if you don't like the ccf block.
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  8. #8
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    Make sure you work in an extremely well ventilated area. Many foams are highly toxic when sanded, cut or otherwise disturbed. Not all of them are, but it wouldn't hurt to be cautious.
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