Foam Sphere

The goal of this project was to create a perfect foam sphere out of a block of high density foam using sur forms rasps and pre made templates.

Two 4"x4"x4" foam blocks were cut out of a large piece of stock using a hand saw

Surforms were used to quickly remove foam and initially to round the top of the blocks.

Initial rounding of foam blocks. Dent marks were placed using a metal template and mallet, to identify areas that needed to be removed.

Foam was sanded until two hemisphere like shapes were formed. The hemispheres were deemed spherical enough once fitting into metal template.

Metal templates used to size check

Hemispheres marked using templates to indicate areas that need to be sanded further

Both hemispheres fully rounded

Bottoms of hemispheres were removed using a bandsaw

Sanded the bottom of hemispheres

Applied a thin coating of wood glue on flat surface or hemispheres

Both hemispheres were held together using a c-clamp while the glue cured

Sphere after glue excess glue was removed and sanded with additional foam piece.

final sphere!

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