Things You'll Need
2- to 4-inch metal pipe or straight pipe fitting
320 to 400 grit sandpaper
Quilt cutting mat
Foam core board
Hard rubber or rawhide mallet
A foam board is a piece of 1/8-inc to 1/4-inch piece of foam covered on both sides with a heavy stock paper. The foam core is either white or black and is used to mat pictures, construct story boards and cover homemade books. A craft knife or utility knife works well to cut through the foam board. Punching a hole through the foam board is a little more tricky. A homemade hole punch from a metal pipe or pipe fitting with the correct outer dimension works well for this process.
Place and secure a length of metal pipe or straight pipe fitting, 2- to 4-inches long, in a bench vise so the pipe length is standing on a vertical line. The holes of the pipe are on the top and bottom. The pipe must be at least 2-inches long so it is easy to hold when punching the foam board.
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Bevel the outside edge of the pipe at an approximate 70 degree angle with a flat file. Reposition the pipe as necessary to bevel the entire circumference.
Remove the pipe from the bench vise.
Sand the beveled edge to remove all burrs.
Place a quilt cutting mat on a solid flat work surface. The quilt cutting mat is used to protect the flat work surface during the hole punching process.
Center and place the foam core board on the quilt cutting mat.
Position the beveled edge of the pipe on the foam core board in the desired location. Make sure the pipe is at a true 90 degree angle to the foam coare board.
Hit the top of the beveled pipe firmly with a hard rubber or rawhide mallet.
Remove the beveled pipe. The cut out piece of foam board will stay inside the pipe when removed. Push a pencil through the beveled pipe to remove the punch.