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Having Alumifoam Issues...

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Hi there folks. Having some issues with my Alumifoam cranks and hope someone can help. This is my process: pour Alumifoam in a 2 part mold. After it dries, there's a mushroom of excess foam where my pour holes were. I sand those down flush and fill in the "scar" with wood putty. Sand that, prime, paint, and do 3 coats of etex on a drying wheel. What happens next is what I believe is off-gasing. My paint bubbles under the etex and then cracks or splits(see pics). I just did a batch and sealed the foam with spar urethane like my cedar lures. Haven't painted or applied etex yet. Any help or suggestions?

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I don't pour foam baits, but it may be that you're not letting the blanks rest/offgas long enough, so you baits aren't fully cured.

You might be able to speed up the offgassing by using a hair dryer to heat the blanks periodically to accelerate the curing process.

If I were using the foam, I'd make some samples, try different curing times and heating, and see if there is a way to prevent the offgassing that is ruining your beautiful lures.

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I tried making foam baits a few years ago and gave up because of the gassing problem. I probably didn't try hard enough, but I made tests with baits as old as 2 months and about 1 out of 5 still gassed and messed up the paint.  I was told later that if you seal them with epoxy before painting it will fix the problem.

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