I've been reading a lot of searched questions and it really doesn't seem very popular to pour your own foam cores these days or everyone just knows how to do it but me. It seems relatively easy but what I'm looking for is mold ideas. How hard is it to make a silicone mold? What type of mold release agents are you using? What type of material for the mandrals (aluminum or steel)
I am going to attempt using pvc and I'm quite excited for the learning process I just wish there was someone to mentor.
Thanks as always, Mark

One of the several RodMaker articles on molding these cores used nothing more than a metal baking tray. Holes were bored for insertion of 4 steel mandrels. You poured the urethane in, allowed it to cure, slid the mandrels out, popped the urethane foam "cake" out and ripped 4 turning squares by cutting on a bandsaw or even by hand. Not at all hard to do.

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First off I've never done this so take that for what it's worth. Makelure.com has video on how to make silicone molds for lures. I would think the application is the same. Good luck!

I have seen PVC pipe used to house the RTV silicone mold, and PVC caps on each end, to center the mandrels. I would think that a sanded dowel covered in mold release would work for making the mold inside this system.. With care, the mandrel hole could be centered pretty well. There a lot of details I am missing, but could be figured out without too much difficulty, I think.

What is a good foam to use for the cores?

I need a core at this moment.

Consider purchasing discounted cork grips and using them for your core.....They are already shaped and when on sale are cheaper and much easier to use than making foam cores. .I've used them in the past and have had no issues........

Unless you intend to make a fairly large number of cores, sourcing already made ones is a better choice, Numerous sources and sizes as well as densities, also economical.

hi Sandy..have you ever tried using EVA for coring these type grips..i thought about trying but can,t seem to learn to like real glossy grips..glossy blanks are more than enough for me...i,m just curious if anyone tried eva.

The foam core, not the carbon skin, is the "magic" behind these grips. Unless you're only looking for aesthetics.

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hi Tom..i guess the magic is the weight..i never handled one, so i can,t really say from experience..Sandy mentioned cork grips for a core and i was just wondering if she tried EVA..i,ve handled lots of eva..lol.

Yep, the foam is important.

Cork is a good damping material. And it is heavier.

is the foam core grip lighter than cork by much after being lathered up with epoxy and covered with a skin? and i think EVA is lighter than cork, i,m not sure of that though.

Yes it is. Most Carbon fiber foam core grips are a bit lighter than cork. This will vary with the density of the foam used. Most grips are made with foam having a density of 6 to 8 lbs per cubic foot. You can make your own foam cores using foam products from United Composites, Fibre Glast, or Aluminite.
Norm