SUPPLIES & TOOLS:
DIRECTIONS:
- Tri Fold Foam Board, 36" x 48", 2
- X-Acto Knife, #11 blade, 1
- Cutting Board
- Loctite, Spray Adhesive, High Performance, 13.5 oz, 1
- Mineral Spirits
- Beacon, Quick Grip, Contact Cement, 2 oz, 1
- Cork, Fabric Back, 27” W x 39” L, 1
- Yardstick
- Ruler
- Pencil
- Scissors
- Rolling Pin or Brayer
- Paper towel
- Spray area
DIRECTIONS:
- Use an X-Acto knife to cut the large center panels (24" x 36") from the short side panels on the Foam Boards. The side panels will not be used.
- Lay one 24" x 36" foam board flat on a spray area. Spray with a thin, even layer of spray adhesive. Stand the two 24" x 36" panels on one short side. Line up the bottom and top corners. Press together. Lay the two panels on a flat surface and roll over the boards with a rolling pin to fully secure. Remove panels from the flat surface.
- Use a yardstick and scissors to lay out and cut one sheet of cork 27" x 39". Lay cork back side up on a flat surface. Use a pencil and yardstick to mark lines 1 1/2" in from each side of the cork panel. These will be the registration marks to locate the foam in the center of the cork.
- Lay foam board flat on a spray area. Spray with a thin, even layer of spray adhesive. Place the spray side of the foam board within the registration marks on the back of the cork. Press lightly. Flip the panel over and use a rolling pin to flatten cork to foam board. Look at cork from an angle to make sure that all bubbles between the cork and foam board have been flattened.
- Flip the panel back side up. Draw a line from the corner of the cork to the corner of the foam. Repeat. Draw lines on the cork, straight out from the sides of the foam board. This will create a large square at the corner. Repeat. Draw a 1/4" square next to the corner of the foam board. This represents the thickness of the boards. Repeat. Mark points 1 1/2" from the outer points of the large square. Connect the point to an outside point of the 1/4" square. Repeat. See photos. Cut as per photo. Small triangles should be on the long sides of the panels.
- Glue long sides first. Apply three long beads of Quick Grip along the back of the cork. One bead close to foam, one down the center of the cork and one close to the edge of the cork. Do not apply glue to small triangles. Start in the center of the length of cork. Pull cork up and around to the back of the foam panel. Press in place working toward the corners. Pull tight to panel. When sides are secure, place a small amount of glue to the backs of the 1/4" triangles. Press the triangles on to the edges of the short sides of the foam board. Hold in place until secure.
- Glue the short sides of the cork the same as the long sides.
- Spray glue upside down into garbage can until no glue comes out and wipe nozzle with Mineral Spirits after each use.