Trying my hand at carving styrofoam in hopes of making an outdoor sign. I just finished my first carving using 2" pink foam from one of the big box stores. I was pleasantly surprised at how well it carved considering I was using a old 1/4" 4 flute tapered bull nose bit. I did find that it left a few "fuzzies" mostly on the vertical edges, but I took my heat gun and quickly re-melted them back down (worked amazing). Not knowing what to expect, I ran my Bosch Colt on 4 and a carving speed of 90IPM doing this in one 3d finishing pass.
I am looking for advice from people who have done this before as to how they go about finishing it so that it can be used outdoors. I have seen a product called Foam Coat that can be applied over the foam to enable it to be painted. I know that if you use the 'real' sign foam that you can paint directly on it, but I am looking for a cheaper option to get started. For starters, I just want to get the foam to a wood color look and from there, maybe add some color to the objects (once I figure out how to use a air brush).https://www.dropbox.com/s/n5tudoeuxoeyt ... R.jpg?dl=0
Thanks for any advice.