Operation Battleboard - Phase One

Step One - Create the foam boards

Tools & material:

• Reciprocating saw or any other tool to cut foam
• Wood file or anything else to smooth edges of the foam.
• A makeshift jig
  
• Carpenter Square
  
• 2" thick foam sheets
  
• Sharpie
• Hunter green acrylic paint 10oz bottle
  
• paint brush
  
• water

1 - Measuring

The first thing to do was to measure out the boards. My game table is two 6'6"x 4' boards. Nice, but was only able to fully cover one board with the 2" foam I had. I didn't have enough of the 1" foam to cover a board entirely. You'll see what I did with that later.

I went about cutting up the boards into six 18"x24" and two 24"x24". This cover one board.

Measured and marked the piece of foam to cut. I used the square to make straight line 90 degree angles with a Sharpie.


2 - Cutting

After all the foam was marked up it was time to cut. I use the reciprocating saw for a quick cut. I had a foam-cutter, but it broken after many uses making hills. Never replaced it. I try to use tools I have on hand. No sense it spending money I don't have.

I created a jig out of some hardwood samples I had lying around. I used bolts and wing nuts to have the ability to tight a top board down onto the foam, making a wood sandwich with a foam filling. This kept the foam stable as I used the saw to cut it.

The jig I have has a guide-board so the blade won't cut into the jig and made the cut straight.


3- Filing

The edges of the foam were a bit shaggy. To make them smooth, I used a wood file. I filed slowly at first, to make sure I didn't break the foam with a violent stroke. I keep the foam in the jig, again to give it stability. The edge came out great, nice and smooth. Any big hunks that were left by the saw, I would take special care not to break the foam by accident.




4 - Layout

I laid the boards out so I could bask in the glory. There wasn't too many of a gaps between each board. The only issue was the table has some bends it it, but nothing too major.




5 - Painting

I used hunter green acrylic paint mix with water(1 part water to 3 parts paint).

It took about 1/2 of a 10oz bottle of paint to do all the boards.

There was some white showing through the paint. I figure once these pieces are flocked it will cover this.



This finished my first step in making the battle board. I will eventually flock it when I get some to cover the whole thing ;)