- Modeling Foam
- Fine Hand Saw
- Fine Hand File
- Different sized drill bits and the bolts your using
- Sized Tubing (optional)
Step 1 Cut your foam
Pick what size handhold you want to make, and cut off a peice of foam about that size.
Step 2 Draw your outline
Draw lines on your foam block to guide yourself in cutting your foam mold.
Step 3 Cut to your desired shape
Cut out the shape of your foam mold using a fine hand saw.
Step 4 FIle to smooth and shape
The saw does a good job of cutting off the basic pieces. Now use a fine hand file to smooth and shape your foam mold.
Step 5 Fine tuning
Finely finish off your custom foam mold to exactly the shape you want. You can file in your own curves and edges for any feel or difficulty.
Step 6 Bore a hole in the foam
It's time to bore out a hole in your foam so that a bolt or screw will be able to go through your final mold project. You will need a couple different sized drill bits, and the bolts that you're going to use to fasten your handholds to make sure they're going to fit.
Step 7 Make the hole large enough
Using the drill bit and a little tube to guid it, drill out the hole for your bolt. Then, using a larger drill bit, widen the top part of the hole so that a bolt head and rachet socket will be able to fit in there.
Now your foam mold is ready to be applied into the casting phase of making your custom handhold!