foam PVC - trade name Foamex in the UK would work - screen printers, digital printers would have offcuts - very cheap and can be easily cut with a craft knife shaped with a hot air gun and moulded without gloves
I'm sure there's a variety of products that would work - thanks for the tip for the UK guys. That must be slightly different from the ''foamed'' PVC I tried.
I advised the glove for safety and ease while heating, and then holding the material on rail.
Hi mike
I saw a shaper do this another way with cling film taped onto the board then used 2" wide strips of cloth and taped them over the rail then glassed them
Nice permanent rail profiles
That's the way I'd done it back in the 80s, it was the inspiration for doing it with the PVC.
Good thing this conversation has continued.
Instead of a durable, thick paper mache,
I think I’ll proceed with layers of appx. 1" strips of fiberglass over masking tape w/ slight vaseline coat, and UV resin. – quick, durable, lasting, and you can write on them.
Any comments on the masking tape w/ slight vaseline coat? --its just my best guess.
Clear packing tape without vaseline coat should work.
otis, I just used wax paper taped at the corners.