Pmullen503 wrote:The problem with heat forming foam, and I've done a lot of it, is the temperature that foam becomes flexible is very close to the temperature that it collapses. That and the need to let the heat "soak" in means you need good temperature control and the ability to hold it there for a long time.
I've been able to heat form foam for RC planes into complex curves but I'm typically working with foam only 1/4" thick. I think I could do 1/2" with the right time and temperature settings. At that point you could laminate several layers to get a usable thickness.
The equipment to do this is more than most one-off builders would want to invest in, but it could be done.
So here is what I found concerning melting the foam.... If the temp stays around 200 it seems to be very stable and it can be in the heat for a very long time. I had pieces at 200 for 30 minutes or more with no melting. Once I got over 220 or 230 is where I started seeing melting.
The biggest issue with my process is that most people don't have access to a controlled oven of an appropriate scale to do camper work. Mode airplane stuff can be done in a toaster oven.
An insulated box could be built out of foam and wood, maybe drywall or steel, within a reasonable budget. A propane burner could be used for a controllable heat source.