Duplicate Boring

Dow uses the acronym "XPS" for "Styrofoam" brand extruded polystyrene foam.
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Kevin Gallimore
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I seem to remember seeing something about expanded polystyrene molding in a microwave oven. If that's possible, then you could make your molds out of wood, which would be a whole lot easier.
Another option might be vacuum formed plastic over a wood pattern.Shouldn't be too hard to cobble up a small vacuum forming rig. You could even buy a Mattel Vacuform - There are plenty of people still selling sheets for it.
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