How To Mold Foam Duck Decoys

For the do-it-yourself duck and goose hunter building decoys from foam is a viable option to create a custom decoy spread. Two-part urethane foam will yield a very strong decoy. Molds made of aluminum are available from multiple vendors and work quite well. Besides allowing hunters to build their own decoys, foam decoys do have several advantages over plastic decoys. Like cork decoys, foam decoys are also unsinkable as they are solid foam. Foam decoys will also hold paint better than plastic decoys, but not as good as cork.
The two types of foam used for decoy building are EPS and two-part urethane. An EPS type foam decoy is derived when EPS beads are placed in a mold and then heated in boiling water. This Top Custom Home Builders Near Me foam is fairly durable and holds paint well. This type of foam is available in different colors. As the decoy paint will eventually wear or chip, black is a good color of choice.
A two-part urethane foam decoy is derived when the two liquid parts are mixed, poured into a mold, and allowed time to expand and harden. This foam is far superior to the EPS type foam. It is much harder, thus more durable. It also holds paint well. No external heat source is required when making decoys of this material. The chemical reaction that takes place when part A and B are mixed will generate a small amount of heat.
When deciding which foam material to use we highly recommend the two-part foam. Although this material is more expensive, urethane decoys will by far outlast EPS foam decoys. Another very important consideration is the safety hazard in using a large container of boiling water that is required to expand EPS beads.
Molds are available for both goose and duck decoys. In most cases the body and head are formed from two separate molds. Decoy molds are usually constructed of aluminum, with some fiberglass molds custom made. When purchasing a body mold an extracting mechanism should be considered. This mechanism is usually a large bolt that can be turned into the mold in order to push the finished product out of the mold. This feature can save you from allot of frustration and is highly recommended. Not all molds have this feature.
A release agent is used to keep the foam from sticking to the mold and will allow you to remove the finished product from the mold. When using a two-part foam car wax in paste form will just fine. When using EPS beads corn oil should be used. We do not recommend using aerosol release agents due to the associated safety hazards.
Large C clamps are used to keep the halves of the mold together. When making bodies we recommend 3″ or 4″ clamps. 2″ clamps can be used for making heads. You will need 4 clamps for body molds, and 2 or 3 clamps for head molds.
Disposable containers such as large Dixie Cups, or …