First I would like to thank Mike for taking the time to do all these tests. Having produced the video i have had time to watch each one several times.
http://www.youtube.com/watch?v=eabrhfZ6ZbQ
I think one of the points gained from these tests is rather obvious but often missed which is that these products need time to "Season" to attain thier strongest bond. Most of the tests were done over 4 and 48 hours, however products containing PVA need to season for much longer and as they do they can gain more strength even after 14 days or more. All the tests were single layers and coats and mulitple layers and coats will add more and more strength to the panels as a whole but not to the bond.
The tests do not show the typical stress that would be applied but will give viewers some ideas of thier bond.
Section 1 - 1 Part Epoxy Acrylic Floorpaint / Cloth / Foam
The 1 part Epoxy Acrylic Floorpaint in these tests was designed for use on porous surfaces and is a covering not an adhesive. Its not designed to be used on foam or other non-porous surfaces.
Section 2 - External Latex Paint / cloth / Foam
The Latex in Latex paint is PVA. PVA is a glue designed to bond two porous surfaces together. It is not designed to bond non-porous surfaces, Foam is not porous.
Section 3 - External Latex Paint / Cloth / Wood
The Latex in Latex Paint is PVA. PVA is a glue designed to bond two porous surfaces together. PVA should bond cloth, wood and other porous surfaces
Section 4 - 1 Part Epoxy Acrylic Floorpaint / Cloth / wood
The 1 part Epoxy Acrylic Floorpaint in these tests was designed for use on porous surfaces and is a covering not an adhesive.
Section 5 - 5 Min Epoxy Resin / Cloth / Foam
IMO this test is the most suprising as Epoxy is used in surfboard manufacturing, the boat and Aero industry and as a foam to foam adhesive. However Loctite Epoxy is not one i have ever seen used and from information on the net it is not the best or strongest. Epoxy does have some flex but is best used to form a hard shell. Notice how the cloth keeps like a solid rather than allowing it to roll with other products.
In one sample you can see the manufacturing logo of the foam comes away and i have a concern that there may be some unseen covering of the foam. Surfboards, boat and aero manufacures all sand the foam to a shape so the outer layer is removed
It maybe that you have to use the correct epoxy resin and hardner. Here are some videos on one product.
http://www.youtube.com/watch?v=8GQxtaqlAHs
http://www.youtube.com/watch?v=BTDFF1Vb_2I
http://www.youtube.com/watch?v=MV5t02Lv24s
http://www.youtube.com/watch?v=K5hzuix3Rak
635 is also a tested product for use with foam
http://uscomposites.com/epoxy.htm
Some epoxy is damaged by UV and some Surfboard makers use Epoxy to cover the foam and them Polyester Resin over that.
Section 6 - Polyester Resin (GP) / Cloth / Foam
GP Resin eats foam
Section 7 - Polyester Resin (GP) / Fiberglass / Foam
GP Resin eats foam
Section 8 - Polyester Resin (GP) / Cloth / Wood
GP resin will stick to wood and cloth, however the cloth needs to have more that one layer for strength. GP Resin does not flex very well and needs to be a solid shell covering rather than an adhesive.
Section 9 - Polyester Resin (GP) / Fiberglass / Wood
This is standard fiberglass skinning of wood a system that is often used. GP Resin does not flex very well and needs to be a solid shell covering rather than an adhesive.
Section 10 - Zinsser BIN Primer Sealer / Cloth / Foam
Listed as a Performance Shellac-Base Primer / Sealer
The product specification says "adheres to glass, metal, tile and other glossy surfaces without sanding"
However it says "adheres to" not bonds so the product is a coating rather than an adhesive
Section 11 - Titebond III / Cloth / Foam
TB3 is a yellow cross linked PVA wood glue for use to bond two porous surfaces together. It is not designed to be used on foam and other non-porous surfaces.
Section 12 - Titebond II / Cloth / Foam
TB2 is a white cross linked PVA wood glue for use to bond two porous surfaces together. It is not designed to be used on foam and other non-porous surfaces.
Section 13 - Titebond II / Cloth / Wood
TB2 is a white cross linked PVA wood glue for use to bond two porous surfaces together. This sample shows what TB2 is designed for.
My conclusions are that all the products have a bond from very poor through to very strong. The ones that should work do work as expected. I feel the Epoxy version may well not be typical and be the wrong product.
The strongest bond was PVA to wood and that should not be suprising as that is what its for (Porous to porous) however PVA does stick to foam but to a much lesser rate.
Remember that Latex paint is PVA as is Titebond II and III.
My thoughts are that i will add wood edging to my foam anywhere there is a stress point such as round doors, windows and the floor joint. The joints would then be a canvas to wood which works perfectly well and where the canvas / foam sections are the foam would be trapped and as such could not move. As my demountable camper is for off road I shall also use more than one layer of canvas.