Had a thought occur to me, and as it technically could fit into at least two "Help" topic categories, figure putting it here in a "neutral territory" would be best.
Has anyone attempted or even considered the possibility of using vacuum forming (or similar plastic shaping techniques) to apply a hard shell over a foam-built piece? I mean the obvious issue right off the bat would be needing to support the foam piece so it isn't squashed or warped by the pressure, but if that could be properly accounted for, would this work?
This idea came out from the often posed question of how best to seal a foam build and hide all the seams, cracks, and other imperfections. I was also thinking this could bridge some of the gaps between foam and fiberglass builds by having the lighter weight of a foam build combined with the semi-rigid construction that comes from a fiberglass build, but without the additional weight that comes with it.
Having no experience whatsoever with foam or vacuum forming, I honestly have no idea if this would even be feasible, and perhaps that is why I haven't seen it brought up before. Perhaps someone tried it, and it failed, so it's been left off the table. Or maybe not. I really don't know. So, anyone have any opinions and/or feedback on the concept? Do you think it's workable? If it hasn't been attempted already, is there anyone willing to test it out? I certainly don't have the means nor the know-how to do it myself, unfortunately.