I am considering making my own crown moldings out of foam using a foam cutter. We want a "straight" model of molding so it should be possible to get the shape right. What I'm uncertain about is if the surface will be good enough to look nice. I was thinking of buying XPS300 or similar, since I imagine they have a better/finer texture. I haven't used polystyrene/foam crown moldings before, so I don't know what the surface is like on the moldings that are available for purchase.

Does anyone have experience with this? Can the surface of cut XPS be good enough to look nice as crown molding? Is "regular" foam (EPS) sufficient?

/Samuel
 
Maybe off topic, but why don't you just take "ready-made" wooden strips?
There are many profiles to choose from.
 
KnockOnWood KnockOnWood said:
Maybe off topic, but why don't you just take "ready-made" wooden moldings?
There are many profiles to choose from.
That's a valid question, I think.

We haven't managed to find any ready-made wooden molding in the design we want (reason 1).

Then I found a molding in the right model (I thought) in foam plastic, but it turned out to be too small; meaning the right model but in the wrong "scale". Before I noticed that the size was wrong, we started thinking that it might be a handy material for ceiling moldings. It's easy to cut, lightweight, and moldable for irregularities (reason 2).

Now that I've started contemplating making them myself, it's hard to let go of the idea (that's a bit of a hallmark for many of us who hang out on this forum?)(reason 3).

Since it's about ceiling moldings for almost the entire house, the cost of the saw becomes small (about 7-8kr/lpm). I estimate the other material costs to be around 3-5kr/lpm, so the total is still significantly lower than buying ready-made (reason 4).

Additionally, I get the opportunity to purchase a new tool that I haven't had before (reason 5).
 
The surface must consist of closed cells, otherwise it's probably impossible to achieve any finish. I don't think it's possible to cut your own.
 
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RoBo
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M mlkjhr said:
The surface must consist of closed cells, otherwise it might never get a decent finish. I don't think it works to cut your own.
That's what I'm worried about, and if it were ordinary cell foam (eps), the cells are so large that it would logically be a problem. However, when it comes to XPS, the cells aren't as large. It's even possible (according to a product description I found) to use sandpaper on XPS. In the product images https://www.conrad.se/?websale8=conrad-swe.01-aa&pi=821035&refKey=Rv_vHICQK, the surface is painted after cutting, but it's not possible to determine the finish quality.
 
Ask a manufacturer to make the molding according to your specifications in wood instead. It costs a bit in setup fees for the machines, but then they will be perfect.
 
It won't turn out well, even if you have an exact jig to saw with, you'll
have to work a lot on the molding before it's suitable for installation.
You'll have to do a lot of sanding.
And you won't be able to make long pieces either, and getting many short pieces
to become long nice moldings is something I, unfortunately, don't believe in; there will be many joints.
Then it needs to be spackled and painted before there is any kind of finish.
I recommend finished moldings, a lot of work for nothing.
 
The ones you can buy at e.g. Hornbach and Bauhaus are probably foiled?

Sure, it's certainly possible to do, but I think there's a risk that it will require some fiddling to achieve a good finish.
 
What should the list actually look like?
Can you perhaps draw a profile with dimensions?
 
KnockOnWood KnockOnWood said:
What should the molding actually look like?
Can you perhaps draw up a profile, with dimensions?
Hello,

It should be like this one, but a bit larger.
http://www.moelven.com/se/Produkter...al/Produktguide---List/Taklist/Trapplist-078/

It might be necessary to order from a planing mill. There will still be orders for casings and baseboards, so the contact already exists. The biggest motivation for doing it myself is currently curiosity.
 
Oh, that was advanced, I've never seen a list like that actually.
I've personally stopped at swanhalslist, advanced enough for me :)

But I also think it will be difficult to mill by hand in foam.
But you can try with a small piece first, so it doesn't get too expensive.

But wouldn't it be possible to build it up with three strips of MDF board?
They are available in thicknesses up to 28 mm.
 
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Sam_u_El
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Thank you all for the responses and tips!
 
KnockOnWood KnockOnWood said:
Wow, that's advanced, I've never seen such a list actually.
I've stopped at the swan neck list myself, advanced enough for me :)

But I also think it will be difficult to rout by hand in foam.
But you could try with a small piece first, so it doesn't get too expensive.

Still, wouldn't it be possible to build it up with three strips of MDF board?
They come in thicknesses up to 28 mm.
Yes, in a way it's advanced, but it's just straight cuts. I haven't planned to rout the foam board, only to cut strips and glue them together.

Good tip about MDF. I'll have to think about that. Thanks!
 
That profile is probably easiest made with a table saw. With a good blade and a bit of precision with the settings, the post-processing will be minimal.
 
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