Making GIANT Letters from Insulating Foam

#foam
I was asked to help make a large display at a church in ATL GA.
This was my first time using foam to create anything, what I learned is when cutting it cut slow as to not over heat it because when it melts it
becomes very textured.
spray adhesive amzn.to/2LduMY4
a 2" thick piece of 4'x8' foam was around $40 from home Depot
Stuff I use in my Shop if you purchase from this link it helps to support my shop at no extra cost to you.
www.amazon.com...

[@queenkitsune4864]

Thank you so much for showing this! Great video all these years later❤

[@ChadsCustomCreations]

So happy to hear you enjoyed this! It’s an oldie for sure.

[@12gageshots]

You really do have a lot of good ideas up your sleeve. *cutting a blade you know you'll never need is a great one.

[@garrywinters6009]

This is AWESOME! Thank you for sharing.

[@ChadsCustomCreations]

Glad you enjoyed it!

[@twthanous]

Good fitting on cutting those letters. Nice work Bro !

[@ChadsCustomCreations]

Thanks a lot!

[@TheTomar33]

Nice job,.

[@tonycabero]

Awesome job!

[@egonzy4473]

Wow that was pretty awesome 👏

[@ChadsCustomCreations]

Thanks so much for watching

[@yourunclesam6780]

Awesome video tutorial .Thanks guy's

[@ChadsCustomCreations]

My pleasure uncle!

[@ronh9384]

Nicely done!

[@ChadsCustomCreations]

Thank you!

[@TheGrantAlexander]

9 inch jigsaw blade that is crazy! Great looking work in the end 👍👍

[@ChadsCustomCreations]

No kidding it was a metal and wood blade too can't imagine what that would be for.

[@TheGrantAlexander]

@@ChadsCustomCreations i have seen them for a sawsall but never that long for a jigsaw!

[@MrBroWnG.]

This was really cool and helpful

[@ChadsCustomCreations]

Glad to hear it and thanks for watching!

[@POPORAZZI]

Love this video. Thanks for sharing.

[@ChadsCustomCreations]

My pleasure thanks for watching.

[@WilliamsPinch]

So satisfying

[@ChadsCustomCreations]

Thank you glad you liked it

[@MikeTheMaker1]

Now I want a giant snow storm to roll through.

[@angelgegege]

Great work, man!! :)

[@ChadsCustomCreations]

Thank you Angel!

[@deborahquidort134]

Came out beautiful!

[@ChadsCustomCreations]

Thank you so much Deborah!

[@yazminsarasino3223]

Amazing great job. Continue to inspire

[@ChadsCustomCreations]

Thank you!

[@ginamoody5105]

Awesome 🎉❤

[@bethp.9009]

Beautiful work

[@ChadsCustomCreations]

Thank you Beth 😊

[@annavazquez4993]

So cool

[@ChadsCustomCreations]

Thanks for watching

[@judichristopher4604]

Wait... What did you SEAL this with? I love a Water Polyurethane... (what they use for like Front Doors) weather proof.

[@ChadsCustomCreations]

If I remember correctly just the paint was all I used to seal it.

[@60sectolive48]

Chad thank you for the video! Question: Which product did you use to "fill" imperfections on the foam? It appeared to be wall spackle perhaps?

[@ChadsCustomCreations]

My pleasure thabk you for watching. Yes wall spackling is what I used.

[@fromamotherspov]

Your work looks so effortless and flawless. I love your idea of spray painting like that! Could one have used spray can paint? What did you use to glue the 2 foam boards together? What did you use to prime the cut letters? What was used to hang the letters at the installation site? Thank you for this video!

[@ChadsCustomCreations]

Thanks so much. So with this foam you cannot use normal spray cans because it melts the foam. I used the homeright sprayer gun with acrylic paint. I used spray adhesive to bond the two pieces. For ha ging installations wr used command hooks velcro straps.

[@fromamotherspov]

Thanks!!! I'm a novice at this but really need to custom create pieces for a non-profit. Your video was perfect. Please post videos on foam cutting machines for this type of work if you ever have the chance. Thanks again.

[@fromamotherspov]

Hi Chad. What is the printing machine that you used to print out your letters. That's very neat and convenient.

[@ChadsCustomCreations]

@@fromamotherspov yes it is amazing it's called a CNC this one is the xcarve 1000mm but if I was to direct someone today to a better machine in the same price range I would say go with the onefinitity cnc.

[@fromamotherspov]

@@ChadsCustomCreations thanks!!

[@judichristopher4604]

BEAUTIFUL SIGN

[@ChadsCustomCreations]

Thank you!

[@ericfischer6351]

Awesome! Did you weatherproof the foam? If so, how? Trying something similar for outdoor application Any ideas would be helpful!

[@ChadsCustomCreations]

My sign was an indoor piece but the foam itself is already impervious to water, the paint also helps. Only real concern is it blowing away because of how light it is or it getting punctured or broken as the foam itself is not super strong.

[@wykeshafuentes9341]

This is my go to video lol....did you use the same blade to cut out the inside of the letters as well (the circular part of the E)? And how many boards do you think I'll need to put together per letter for them (4 letters in total) to be a sturdy table top?

[@ChadsCustomCreations]

Yes I did use the same blade, and something I wish I did was to not run the blade speed too fast as I did cause it caused the foam to melt in some places which required a lot of filling and sanding.. not fun. I think style font you use and how bold the letters will determine how sturdy it will be.

[@wykeshafuentes9341]

@@ChadsCustomCreations thank you

[@thepittsfamily]

My mom asked me to make letters for her yard to spell out Merry Christmas. I’m figuring 2-3’ per letter and trying to figure out what material to use other than PT plywood. Thoughts? Does this foam hold up to moisture and exterior use? Thanks

[@ChadsCustomCreations]

Yes holds up great to moisture my only worry is wind since they are so light weight you will need to make sure they are secured somehow.

[@msclassylady6620]

Thanks for sharing , question what type of paint do you use for a foam board because spray doesn’t work for me it melts the foam

[@ChadsCustomCreations]

Yeah I learned the same thing while making these. I used acrylic paint and I used the homeright paint sprayer. All can sprayer paints would eat the foam even a can of acrylic spray paint are at it.

[@platinumluvxoxo]

Hi what was the pink putty you were adding to the letters and why?

[@ChadsCustomCreations]

That was plaster I had to use that to fill in some of the rough cuts that I got from going too fast when cutting. The blade got Soo hot it melted the edges this was my solution to smoothing everything out. If I did it again I would just cut slower or have a cup of cold water near by to cool the blade down in-between cuts. Could have saved me hours and hours of my life....

[@JasonPeltier]

@@ChadsCustomCreations Look up the Amana 46292-K for cutting foam. Nice video!

[@judichristopher4604]

I am back to Watch this GREAT video AGAIN... NOTE: Please do NOT sped up your video... We want to SEE everything you do... if we want to sped it up... we can.. I love watching you do your ART.... Fantastic ART. SLOW it down Speed Racer... LOL

[@ChadsCustomCreations]

Haha thanks for watching!

[@mmopcreativestudios9678]

A M A Z I N G

[@adamathypernerd7728]

Great video! What bit did you use to cut the foam?

[@ChadsCustomCreations]

I believe it was just a straight cut bit 1/8 one of the cheap ones on Amazon

[@jojopaisley]

Not msg... MDF! 😂😂😂

[@fordguyfordguy]

Can you ever coat foam letters for use in an outdoor sign application?

[@ChadsCustomCreations]

Absolutely, you could coat them with epoxy, fiber glass, or even bondo to give them a hard dent resistant exterior.

[@poultonprojects]

Great video sure like the way you made this do you use a projector To draw it out?

[@poultonprojects]

Man this turned out great!!

[@ChadsCustomCreations]

Yes I used a projector for the larger letters, was able to use my CNC for the smaller ones.

[@roselater]

@@ChadsCustomCreations hi there! what kind of projector do you use?

[@ChadsCustomCreations]

@@roselater the one I got back then is no longer available but this appears to be very similar amzn.to/2XQkTps

[@00Divalicious00]

Thank you soooo much for this video! What was it that you used to cut it and then what was that little spinning thing you smoothed it with? Thanks!

[@ChadsCustomCreations]

The big pieces I cut out with a jigsaw, the smaller letters I fit into my machine called a CNC and I believe I may have used my orbital sander to help smooth it out.

[@guadalupesrodriguez8157]

Which jigsaw did you use ? Or do you recommend one for beginners ?

[@ChadsCustomCreations]

Here is the corded version of the one I used. www.amazon.com/dp/B00OZEUL7Y?tag=onamzchadddow-20&linkCode=ic5&ascsubtag=amzn1.infl.us.product&creativeASIN=B00OZEUL7Y&ref=exp_chadscustomcreations_dp_vv_d&th=1

[@BCalderon-x1r]

Did you use same brand paint for the white?

[@ChadsCustomCreations]

If I remember right it was actually a gallon of outdoor white paint that I had already.

[@TBAKER513]

Hi i just discovered your video. I'm on a mission myself.. can you please tell what kind of projector you are using for this project.

[@ChadsCustomCreations]

It’s just a cheap Amazon projector nothing fancy just make sure you have a way of getting your artwork onto it.

[@TBAKER513]

Purchased one..i forgot to ask what did you use to seal the edges

[@ChadsCustomCreations]

@@TBAKER513 what I used on the edging was just drydex spackling but if you don’t burn and tear up your edges with the jig saw like I did you could just sand the edges smooth. I ran the saw too fast and it melted it like crazy and made for poor edges.

[@wykeshafuentes9341]

Hi would this type of foam be good for 3d letters under a table for a baby shower?

[@ChadsCustomCreations]

Absolutely

[@UjjwalKumar-gl3rr]

❤

[@ChadsCustomCreations]

😘

[@brooklyn2rome]

Can I make these to float inside my inground pool or will they SINK

[@ChadsCustomCreations]

They would definitely float

[@jojopaisley]

Ummm....Please don’t laugh, but can I use this foam to make a console table and small cabinet? I know I could get plywood or msg, but I don’t have power tools, nor do I want anything too heavy! 😕 I really hope that isn’t a stupid question! 😂😂

[@ChadsCustomCreations]

I believe that as a prop you could use this foam for stage furniture but as far as furniture that people would touch or put things on it's just too soft and wouldn't hold up. With all that being said I think you should get some power tools! If you are wanting some good plans to start out with go Google Anna white woodworking plans they are great for beginners.

[@jojopaisley]

@@ChadsCustomCreations Ok! Thank you for responding! 😃 I’ll look her up!

[@shanicelove9584]

How can I book you for a project? I’m looking to have some letters made to use for a storefront

[@ChadsCustomCreations]

You can shoot me an email with the details at [e-mail] and we can see if we can help each other out.

[@savvicreationz4367]

How do you use the projector to help you with the letters?!

[@ChadsCustomCreations]

I used the projector to project onto the foam and traced out the projection with a sharpie.

[@DrPorkchops]

I've never actually been the first to comment on a video. ...is this what all the fucking fuss is about?

[@ChadsCustomCreations]

With my videos you can literally be the first even a week after it's posted. 🤪

[@daphnesimpson5009]

Hi, what projector are you using?

[@ChadsCustomCreations]

I can’t remember the exact one but this one should be same price but way better a.co/d/bV6rCgD

[@BCalderon-x1r]

What type of bit are you using?

[@ChadsCustomCreations]

I think it was like a 2” straight cutting bit.

[@beshebabarnes3004]

How much could one charge for something of this size?

[@ChadsCustomCreations]

$1000 or more

[@riversidebanners]

What type of paint did you us?

[@ChadsCustomCreations]

I can’t remember the brand but it was all acrylic paints

[@riversidebanners]

@@ChadsCustomCreations I noticed it was R-10 150 is that the 1" 1/2 thickness?

[@ChadsCustomCreations]

@@riversidebanners no these were the 2” I believe the R is the insulation value of it

[@riversidebanners]

@@ChadsCustomCreations Did you buy the acrylic paint at Hobby Lobby, or Michael's

[@danielparra6175]

What cnc do have or recommend?

[@ChadsCustomCreations]

I have an xcarve which is good but I would recommend looking at the onefinity now

[@chelsearush7812]

How much was the XPS foam?

[@ChadsCustomCreations]

It is about $30 per 4x8 foot sheet

[@janetcastillo9435]

This foam float?

[@ChadsCustomCreations]

Yes definitely

[@shandreialanee495]

What kind of printer thing is that?

[@ChadsCustomCreations]

I believe you are referring to the CNC machine that one is called the XCarve

[@judichristopher4604]

EXCELLENT VIDEO... Great Information... Great Filming/Editing... but the background NOISE/Music was Ear Piercing... and too loud. I had to Mute this video.

[@ChadsCustomCreations]

I appreciate the constructive feedback. My newer videos I have completely stepped away from any background music at all.

[@judichristopher4604]

@@ChadsCustomCreations Thank YOU SO MUCH

[@riversidebanners]

what tooth count blade did you use?

[@ChadsCustomCreations]

I am sorry but I really can’t remember

[@riversidebanners]

@@ChadsCustomCreations Did you mix the acrylic paint with water?

[@ChadsCustomCreations]

@@riversidebanners with that homeright sprayer you don’t actually have to thin so I believe I didn’t add water.

[@JourneyMapsLiveandLocal]

How did you attach it to the wall?

[@ChadsCustomCreations]

We used velcro command strips

[@JourneyMapsLiveandLocal]

@@ChadsCustomCreations Ok...thanks man. I'm building a foam sign that needs to hang outside on a stucco wall. Trying to find what might work. Any other ideas?

[@ChadsCustomCreations]

If you want it permanent maybe contruction adhesive.

[@JourneyMapsLiveandLocal]

@@ChadsCustomCreations It's not a permanent sign. It'll be on my house just for Halloween.

[@ChadsCustomCreations]

@@JourneyMapsLiveandLocal yeah I would try the command strips then as long as the texture is not too bumpy they should do well and shouldn't cause any damage.

[@MzItzie13]

How do we order?

[@ChadsCustomCreations]

You can inquiry with me at [e-mail]

[@candidosalas7272]

Que material es

[@ChadsCustomCreations]

espuma aislante

[@gaberialbooker]

What did you spray to get the foam to stick together to make it thicker?

[@ChadsCustomCreations]

Spray adhesive amzn.to/2LduMY4