Blade was dulling at the end of the shoulder. So I’ll be going through a lot more blades than I thought. The issue of the seems arise from creating a sharp bend. I cut a channel like thing in the foam so it folds easier but they are never perfect as it either goes through the foam or does not remove enough or on the right angle making the pieces not want to join together in a nice fashion.
Great job! If you're having trouble getting crisp lines, remember, sharp blades! I use exacto knives for all my cuts, they product very clean cuts. The gold blades Ibe found cut the cleanest and sharpest.
This is a sticky subject. This is where higher density and more expensive foams are handy because they dont have as many imperfections and pours. That is a big pro over the convinient and cheap floor mat foam. I would thing your best bet would be finding a good paint(primer, sealant, the whole nine yards) that will cover up and smooth out all these imperfections. You can also take a putty knife and rub woodland scenics foam putty into the holes in the foam, hopefully filling them in, but some are sooo small I wont guarantee it will be perfect... ExCeLLuR8 , how is your paint working? How minimal are the creased and poors, while maintaining a good detailed score?
Re glue it, if you used contact cement, you didnt let it dry long enough, or it was left out all day and lost its sticky-ness. If you used multiple coats it sould be more than fine.
Bad seams can come from stress of the foam wanting to straighten out. Before adhering parts that are curved together a good idea would be to take a heat gun, warm up the foam and curve them into shape.
