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Styro Foam Hills?
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I cannot say for sure how much a 1-pound bag will cover, but I do know that it covers a lot more than you originally guess it will. As I said, I mix about 50-50 Celluclay with other admixtures; if you used the Celluclay alone it would only cover half as much. <br /> <br />As for the underframe, yes you need something, and I prefer something solid. The Celluclay mixture is just a thick paste when you apply it. Either use Styrofoam or EPS board which you have carved, or what I prefer to to use expanding foam sealer. I get this stuff called Great Stuff, and it's around $4 a can, and it has a long straw for a nozzle. You spray it wherever you want a hill to grow, and it expands a lot. You can, of course, carve it back like regular EPS board once it has cured, but the cool thing is that all the random shapes you get out of it can start to suggest interesting landforms; a sculpted-in-place coating of my Celluclay mixture can transform those yellow bulges into boulders and cliffsides. The expanding foam needs something to adhere to, so for that I might use chicken wire, or else cardboard, or if you're not going too high with it, you can just build it up from your tabletop (if you've built your layout that way). You could probably mix foam boards and expanding foam, using the boards for the low slopes and the Great stuff for the terrain "features", but I'd make sure to do a chemical compatibility test first (the Great Stuff might disolve the foam board). Great Stuff is easy to find at hardware stores; it is used for insulating wall cavities, such as around doors and windows. <br /> <br />I think you can get big sheets of styrofoam (or EPS) at hardware stores as well.
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