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How to Create Custom Foam Hollow Rocks for Outdoor Speakers
Ez-Spray® expandable rigid foam is often used to create large, lightweight elements used in landscaping.  It also increases productivity by reducing production time.  In the following example, the goal is to create custom, hollow, rocks for the purpose of concealing and housing outdoor speakers that blend in with exterior landscapes.

Using a Rebound® 25 mold previously used to create decorative rocks cast in concrete, the landscaper quickly employes the 
EZ-Spray® system to quickly produce durable, lightweight castings. Outdoor speakers are mounted inside. The rock speakers ad concealed audio ambiance to any environment.   
 Ez-Spray® foam cartridge is opened by prying off the tip of the cartridge.  Note -  gloves are recommended when working with any materials.

1 - Ez-Spray® foam cartridge is opened by prying off the tip of the cartridge. Note - gloves are recommended when working with any materials.
 A flow regulator (included) is installed before adding the static mixing tube.

2 - A flow regulator (included) is installed before adding the static mixing tube.
 A static mixer (included) is installed on the cartidges.

3 - A static mixer (included) is installed on the cartidges.
 The collar is tightened over mixer tube.

4 - The collar is tightened over mixer tube.
 Cartridge with mixer is loaded into the EZ-Spray® gun and the air line hose is attached.

5 - Cartridge with mixer is loaded into the EZ-Spray® gun and the air line hose is attached.
 Material is started through the gun by ejecting a small amount into a waste bucket. This is done to insure a good mix and to put only well mixed material into the mold.

6 - Material is started through the gun by ejecting a small amount into a waste bucket. This is done to insure a good mix and to put only well mixed material into the mold.
 Rebound® 25 brush-on mold complete with support shell is positioned for spraying.

7 - Rebound® 25 brush-on mold complete with support shell is positioned for spraying.
 Wearing a Niosh approved mask, the landscaper delivers an even coat across the surface of the mold.

8 - Wearing a Niosh approved mask, the landscaper delivers an even coat across the surface of the mold.
 The foam quickly begins to expand and form the hollow shell.

9 - The foam quickly begins to expand and form the hollow shell.
 Another quick coat is added to ensure a strong, even piece.

10 - Another quick coat is added to ensure a strong, even piece.
 Foam is allowed to fully cure before demold.

11 - Foam is allowed to fully cure before demold.
 The Rebound® 25 silicone glove mold easily peeled from the casting.

12 - The Rebound® 25 silicone glove mold easily peeled from the casting.
 The finished casting displays excellent detail.

13 - The finished casting displays excellent detail.
 Extra material is carefully cut away with a utility knife.

14 - Extra material is carefully cut away with a utility knife.
 Taupe color spray enamel is sprayed on to the surface and allowed to dry.

15 - Taupe color spray enamel is sprayed on to the surface and allowed to dry.
 A polyurethane stain is brushed over the surface to add variation and depth.

16 - A polyurethane stain is brushed over the surface to add variation and depth.
 The faux rock speaker blends in to surrounding landscape delivering audio ambiance.

17 - The faux rock speaker blends in to surrounding landscape delivering audio ambiance.
 The manufacturer offers several sizes and finishes.

18 - The manufacturer offers several sizes and finishes.
 Several custom speaker rocks were installed around the property to deliver balanced audio without being offensive to the natural landscape.

19 - Several custom speaker rocks were installed around the property to deliver balanced audio without being offensive to the natural landscape.

                   
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