DIY Aluminum Foil Hack – Protective Barrier for Polyester Resin – Foam Hard Coating Techniques

Here's an easy DIY aluminum foil idea for protecting your foam project melting with polyester resin. Using a tin foil layer as a protective barrier is an old foam hard coating technique that really works. Protect your foam sculptures and props with cheap and inexpensive aluminum foil before you apply fiberglass resin or hard coatings that can react, melt, or damage your hard work. Using a watered down wallpaper glue and thin aluminum foil could save you money with your project instead of using many of the foam safe epoxy resins and foam coats. You can also apply the aluminum foil to the EPS/polystyrene using a spray glue like spray 77 but I only spray it on he foil and wait a couple minuets to help prevent any melting. You can also use the sticky back or adhesive aluminum air ducting tape. I was able to find it in 2" wide but there are a few larger rolls available online. In this video I show the quick tin foil tip as I continue work on our Masters of the Universe Castle Grayskull jaw-bridge. The Giant size He-Man playset is one of the largest fiberglass and polyester resin projects we have ever worked on. Let's just say the next one will be a little smaller. We have made a lot of fun projects but this one has been one of the most labor intensive one I can remember. It should be cool when it's finished. Now this castle doesn't have any super crazy fine details but I was surprised that the foil doesn't cover the little details I do have. If you are carving a foam prop or sculpture and want to hard coat it with something that melts EPS foam give this method a try.

Here's the link if you would like to check out the epic castle build
Giant He-Man and the Masters of the Universe Castle Grayskull Playset

Another video that goes into ore detail on the fiberglass process
Protecting Foam and Creating a Strong Surface 💀 Hard Coating with Fiberglass

"Music by Karl Casey @ White Bat Audio"

Amazon links
Wallpaper and Border Adhesive
Professional Grade Aluminum Foil Tape
Aluminum Foil Sheets
3M Super 77 Multipurpose Spray Adhesive
Stainless Steel Curry Comb

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DIY Aluminum Foil Hack – Protective Barrier for Polyester Resin – Foam Hard Coating Techniques

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