How to Glue Foam Core Flat
This article will take some liberty and use the term "glue" in the title to mean adhere. The options discussed will progress from least to most permanent. The article assumes mounting foam core to some sort of substrate. All methods should work to flatten the material.
Things You'll Need
- Flat Table or Section of Clean Floor
- Sharp Razor or X-Acto Knife
- Rigid Substrate Material (e.g. masonite)
- Velcro Tape or Buttons
- Double Face Tape
- 3M Adhesive Mounting Sheets
- Contact Cement
- Wax Paper
- Pressure Roller
Instructions
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Prepare, Choose Option, Trim to Finish
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No matter which adhesion option you select cut the substrate material to be square and about ¼" to ½" smaller on all sides than the foam core you will mount to it. You will trim the excess foam core to the exact size of the substrate when finished.
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2
Velcro is sold in variety of forms including rolls and as "buttons" on sheets. If using the tape, cut the length to end up with squares. Remove the backing tape on the hook side of either the squares you made or the buttons and affix them every few inches to the perimeter of the foam core, about ¾" to 1" from the edge. Remove the backing from the loop side of the Velcro, position the foam core to the substrate and use a pressure roller to make sure the buttons adhere to the substrate. You will be able to remove the foam core if it gets damaged.
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3
Double face tape is another possibility. Lay a strip around the perimeter of the foam core, peel off the protective backing if present, and use a pressure roller to press the tape in contact with the substrate. With some effort, you may be able to get the foam core off the substrate.
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4
3M and other manufacturers make adhesive mounting sheets that will cover the entire surface of the foam core. Following the manufacturer's instructions, remove the protective sheet from one side of the sheet and press firmly in contact with the foam core. Use a pressure roller to make solid contact. Trim any excess that overhangs the foam core. Remove the remaining backing sheet and a thin layer of adhesive will remain on the foam core. Mount the foam core to the substrate, cover the front of the foam core with paper for protection and use the pressure roller to make firm contact.
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5
Contact cement will permanently bond the foam core to the substrate. Apply a thin coat of the adhesive to both the back of the foam core and to the substrate and allow it to dry on both surfaces. Place a large piece of wax paper on the substrate and position the foam core on top of it. Gently slip out the wax paper and allow the two surfaces to meet. Using a protective cover sheet on the front of the foam core, pressure roll the two surfaces together.
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Place a scrap piece of wood or cardboard on a clean table or floor. Cover the surface of the foam core with a piece of paper to protect it. Place the foam core and substrate face down. Using a sharp razor or X-Acto knife, use the substrate edges as a guide to trim the foam core to the exact size.
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Tips & Warnings
If using contact cement note that once the two adhesive surfaces meet, you will not be able to get them apart. That is why the use of wax paper is recommended until you have the two layers aligned.
