New answers tagged materials
It's called HDPS (high density polystyrene) Most commonly used in decking. Some is a direct replacement for wood, and yes it is expensive. But your deck will last much longer without maintainance. It comes in different densities and the lighter the greater the r value, but the lower the strength. Unfortunatly there are pretenders in the market place. HDPS ...
Laminated MDF is the typical form material (aka, prefab shelf boards). You can usually get the laminate in strips (for backsplashes and edge-banding counter tops). I'd make the square parts of the form, then use several layers of the edge banding laminate to create your curve. Create a curve template out of plywood, then glue the laminate around the curve.
Any type of thin plywood will do. Cut it into 6 inch strips and it bends easier. You might need two layers. Intalls the strips inside your frame, don't use the strips as your frame.
1/4" birch underlayment plywood (Tecply) should take that bend even without kerfs, moisture or heat. I'd probably double or triple it (without fastening together) for stiffness. Build your form out of lumber, then either rabbet the lumber for the plywood to achieve a flush joint, or lay plywood all the way down the 2 sides adjacent to the bend.
How can you call such a mat? The general name for a long thin protective mat is a runner. Walmart "Vinyl Runner".
Joint compound needs air to grow mold. So before you are putting lid on, flatten the compound surface level and then add a couple inches of water, then put on lid. Also if you have mold in your compound just throw it away. Would you want moldy materials put in your house?
Mold grows on any surface that provides food for growth. Joint compound contains organic compounds and lots of moisture. The compound will only last a finite length of time even under "ideal" conditions (if mold spores don't ruin it drying-out will). To slow down its' expiration time: when storing the compound for any length of time, place the plastic ...
Mix in a bit of chlorine bleach. It won't affect the compound and the odor dissipates fairly quickly upon use.
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