: For a kayak plug I used 2 inch pink styrofoam insulation from the lumber
: yard, roughly shaped and laminated together with construction adhesive.
: This material carves easily with a wavy-edged bread knife. Be careful not
: to let the adhesive get too close to the surface of the plug. Fine shaping
: was done with lightweight, sandible drywall mud, and finished off with a
: coat of epoxy paint, and the usual waxing and mold release. The mold
: separated from the plug with no trouble. The plug was formed on a sheet of
: cheap, waxed paneling, so I was able to get a flange on my molds.
: Everything I needed I got from the local building supply.

Hi Tom

Great info. Could you spend a little time to tell how you made the drywall mud stick to the foam without cracking off or whether it's even and issue?

(Even though one would use more layers, aren't we all in a way just finishing the glass over a plug(in our case sanded strips that we keep), so how crude does the surface get on your foam plug. Could it be readily sanded down to make another positive? I believe some kitplanes are built this sorta way, but I really like the simplicity of readily available materials.)

So for a slick surface, can you smear the putty on thin? Or is it just good for filling holes and mistakes?

-mick