I am looking for thin polyurethane foam sheets

Just wondering if anyone wants to sell some polyurethane foam scraps. They could be pieces cut off to make a board, perhaps where the board was considerably thinner than the original blank and they were sawed or hotwired off. I may have to simply buy a block of foam and hotwire my own - if I can't find anyone who already has them hotwired or who can do this in a pinch, I will simply have to buy and hotwire them myself, but I thought I'd ask first what might be out there, and how much you would want for it. I'm not in any emergency situation so no hurry.
Thank you.

 

True, hotwiring is normally done to EPS foam. I would perhaps need a saw. I just want some thin sheets of polyurethane foam - about a 1/2" or even less in thickness. In a sawmill, they would just run a block of wood through a saw and cut it. One could probably do the same with polyurethane foam. However, I really would like sheets that are the same size as typical foams - say 24" x 6 - 8'. I would take stuff only 3' long if that's all there is. I'm really just challenging myself to think how I would cut such a piece of foam if this type of thing isn't around handy. I don't think that it would be easy to do with a planer without making a mess. I'm sure that I could use a handsaw on a polyurethane blank though, and come up with usable (thin) sheets of foam. It just takes some patience. I've decided that I'll just use a handsaw on some block foam. Done deal.

 

What am I doing?

I need the scraps to fix and alter old boards. But in this case, rather than fixing a small delamination, I am fixing a major portion of a board, and I would like to do it without putties or cabosil/resin mixtures to get the best strength/weight ratio. I could just cabosil but this method could be better in the long run. It just takes more patience.

 

A thought occurred to me that I might try some strips of wood. I have shaped wood fins and they are perfectly fine - I've done cedar all the way up to Brazilian Walnut. I just have to decide what strength wood I want to use for the purpose at hand. It might work to use wood. Easier to find wood than strips of foam. Hah-hah.

 

I might give foam a try

When I first thought about this issue, I looked into pour foam. At first, I felt that it might be too expensive compared to just using shavings. And I wanted something higher than 2lb. density - I wanted like 8lb. But when I priced it out, it's like at least 40 or 50 bucks and I was worried that I might ruin my board. But I'll still look into this. Thanks for the link - it looked pretty easy there but it's not as easy to pour foam onto a board. But I can put a piece of 24" plywood over the board and weight it down. It might work since it's a concave I'm filling in. Who knows?

 

It's a valuable board in the sense that it has no major flaws and I caught 30 waves on it yesterday, but it doesn't plane properly hence my altering the bottom's shape. It's just an ok board - but boards are like animals - they are all cool in their own way, irregardless of how ugly they might be to a girl.

 

Correct me if I'm wrong, 2lb. density might be enough, but 3lb. would be better for heavier surfers or tow-boards or guns. I think I need at least 3lb. density or I'll wind up with too many pressure dings.

 

Once I get the property density of pour, I guess my biggest issue is how to keep this thing from blowing the lid off when I try to seal it in. I don't really know how well I can contain the pour inside the concave of the board. Obviously, I will need a clever way to either pour through a hole and seal it. It sounds like a challenge but I don't think it's real difficult - I am only flattening about 3 or 4 feet of the board - essentially, the front section (towards the nose) of the board.

 

I'm not really crazy - just patient since it's not an emergency. But catching waves is one thing, ..., the board stinks. I have other boards that are better. I just want this particular board to be better also.

But I might just make a concrete cast by using some spars for the shape and then pouring into that outside with a real tight lid. So if it tries to blow the lid, no big problem. The hardest part here is to get the right shape. I could first make a plaster or bondo cast then use THAT shape to make the concrete mold. Then pour into the mold. Tedious but at least there is 0% chance of ruining the surfboard since all I have to do is peel the foam off the concrete and set it in the concave with some stickum, then glass over it. Might need some wax paper or surfboard wax to make sure things peel off smoothly. But this way I don't have to surform off a heap of foam.

If I just pour some in the concave, it will rise pretty darn high and involve a lot of surforming.