The rough armature for the robot body was a great place to use this less dense foam. It needed to be fit around the welded steel armature and then roughed into shape. I used there layers of 3" four pound foam. Since I was going to coat it in sculpting epoxy I wasn't concerned with gaps or rough edges. I used PB Bond fat set which cures in only one hour. I glued it up before I went to lunch and when I returned I was able to remove the clamps and get busy sculpting over the new form.
I used crumpled tinfoil to fill the gaps and holes and then pressed on a layer of sculpting epoxy. Once this had set I did another layer that was detailed. In a few hours I did the legs and the bulk of the front of the robot body. Rather than my usual rivets I opted to sculpt flat head screws for more of a retro feel. Tomorrow the bulk of the sculpt should be done. Stay tuned...
