---I made some punches from tubing bought at a hobby shop.  I got a bag of about 500 
assorted sizes, from 1/16" to 5/8 inch in brass, copper, aluminum and steel.  I 
sharpen the end with a Dremel or a file.

I bought a couple of colors of kneeling cushions at Home Depot, and a couple of pairs 
of cheap flip flops in other colors.  W.Mart has some "noodles," for swimming in 
various colors.  Any of these provide more closed cell foam than you'll use in a life 
time.

I cut cores from the foam by turning the home made punches by hand, or some will fit 
in my hand drill - we ain't cutting granite here.  The drill cuts smoother, but 
manually works.

I then put a large needle in my dremel and poke it through the foam core.  It'll hold 
pretty well all by itself.  You can then hold an emery board against the foam to 
smooth it up or to shape it any way you want.  I've glued up some black and yellow 
sheets, bored them, and formed bumble bee bodies from it.

There's a good site (though I think he got a bit more elaborate than needed in his set 
up) that describes this technique in detail, with pictures at
Global Fly Fishers.com
Steve,
In Maryland




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