Project M1911 gets its shape from the polystyrene foam that was cut previously.  An ABS plastic pipe will run through the center of this foam to serve a few purposes:

  • Add rigidity and strength to the structure
  • Provide the barrel detail at the business end
  • Provide a mounting base for display

These layers and the pipe will be held together with epoxy resin.  The polystyrene and ABS are very compatible with epoxy resin as a bonding agent.  These materials must be free of contamination.

A pathway was carved through the center of the foam to create a passageway for the ABS pipe.


pipe path copy

Everything is dry-fitted, and the epoxy resin and associated materials are gathered for use.


Next, both sides of the bonding area are coated with epoxy resin.  Epoxy bonds best when both mating surfaces are coated with resin.

resin abs copy

Next the ABS pipe and layers of polystyrene foam are layered together while coating everything with resin.  Alignment is maintained carefully because the epoxy adhesion is permanent.  Some areas have gaps.  These areas require the epoxy to be used with filler agents to help bridge the gaps.

glueing layers


The entire stack is allowed to cure for 24 hours before it is moved.

The next step is to create the final shape of the foam.