dreadnought72.. Good morning Sir, the sheets are simple expanded polystyrene sheets that we found in TV and Refrigerator packages.. this one sheet almost spans in to 3 feet and about more than 1.5 feet wide.. this one sheet costs about Rs 20/- each here.. and some times i collect those sheets from nearest TV show rooms as they all put those sheets in fire to avoid mess.. but nowadays i purchases it with the help of my friends as it is too hard to walk.. the glue used to laminate the sheets is nothing extra ordinary, but simple white glue, or here known as PVA glue, or Poly Vinyl Alcohol based adhesive that used in wood industry.. here one of the greatest brand is named as Fevicol.. but when i makes longer crafts and for rough use i use the same brand glue, but in to MARINE.. Fevicol Marine is a same white glue, is based on some water proof medium.. i hope this may be the base of acrylic emulsion wall paints.. means after drying it will become water proof.. this is a grace to us in many means.. this glue also can be used in boats using IC engines , means we can apply two or three thin layers of glue, inside, then after proper drying this coating become stiff and strong,and acts as a protection against water entry and fuel damages.. 1 Kilogram of glue costs me here about 80 Rs/- as the seller gives me with discount, as he knows me from child hood..
the tissues.. the tissues that i am using in my works is simple face tissues, is very inexpensive 6 Rs/- for a packet, contains 100 numbers of tissues, in to 12 inches square, is absorbs diluted glue easily and instantly snugs in to the shape of the hull.. or wing.. or on anything.. a costly thick high quality tissue is not a good alternate as they wont absorb the glue easily and rips off when we apply.. the method of application is easy.. dilute the white glue ordinary as SH, or marine as MR, with water.. ratio is 25:75.. means 25 % glue and 75 % water.. then place the hull on a convenient place and place one tissue as spread over the desired place of the hull.. then take a flat brush of 2 inch at least, dip in glue, wipe excess glue and stoke over the tissue.. avoid repeated strokes, as the tissue ruptures.. we can apply 5 layers of tissue at one time.. and must leave to dry.. after drying we can repeat the proses up to 20 to 25 layers or more on bigger crafts.. for this we must leave a 2 mm margin when happing the hull at beginning.. because the tissue and putty takes a little thickness when we starts to work.. after proper drying we can sand the hull for smoothing with 120 grit sand paper, then apply a coat of red oxide for great protection.. when this stage, the hull will be stiffer like a rock.. nothing can match the strength of the hull in this stage as wood, FRP and on..and this will not crumble or splatter in a severe crash, but squeezes the place of impact.. weight is the main criteria of a thermocol hull.. the final weight will be very very less with this method.. after the application of red oxide, we can start the final works..
the final surface preparation is based on two materials.. the firat one is very inexpensive but 100 % efficient and effective.. is the NC based putty.. NC is nitro cellulose..and the word putty is stands for car body finish fillers.. this will be in to a grey colour, and gives us a smooth finish when finished.. after the application of red oxide over the hull, we can finish the rest as usual, that we follows on same balsa or wooden or metal hulls.. the second option is the PU based car body filler.. but this one converts the hull in to brittle in a crash, and makes heavier.. one of the main advantage working on these hulls are easy shaping and finishing.. we can make any complicated shape with a piece od sand paper.. and if you need a build log of thermocol hull i will post it in detail.. because once we mastered the idea.. nothing can stop making boats.. because its 1000% less easy when compared working on a wooden hull.. no cuts.. no jig sawing.. no pins.. no complicated ideas.. but any shape.. any size.. and another good thing is this one is never attacked by borers or termite.. lives for a life time.. this will not affected by climatic changes.. you can leave this crafts in direct sunlights or bone chilling cold.. the fading aspect will be the paint.. so working on.. and on...