How to Shape Upholstery Foam in a Wedge

Flexible polyurethane upholstery foam is used to stuff sofas, chairs and mattresses, as well as many other household items. Upholstery foam is also popular with crafters -- when coated with several layers of acrylic sealant, it can be buffed and painted for use in costuming and other projects. Commercial foam fabricators use vertical band saws and horizontal slitters to carve and shape the foam, but crafters and do-it-yourself workers can get similar effects with sewing scissors and an electric meat carver.

Pen
Electric meat carver
Scissors
Fine-grit sandpaper

Instructions

- 1
  Determine the length, height and slope of your wedge. Measure these proportions on the foam block, and use a pen or marker to mark the cut lines.
- 2
  Nick the corner of the foam block at the cut line using the scissors. A 1-inch opening is plenty.
- 3
  Insert the meat carver into the nick, and press the trigger. Follow down the cut line holding the carver parallel to the cut. Repeat for all sides of the foam. Be careful not to compress the foam while cutting.
- 4
  Lift the top layer of foam from the wedge until the foam that still connects the two is exposed. Cut through this, rotating the foam to make a complete cut. Discard the excess.
- 5
  Use the meat carver to carefully cut away any missed areas, and sand with fine-grit sandpaper until smooth.

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