Hi everyone, I'm new here.
I will go straight to the point.

Query 1. I need a hard material for a DYI project, for constructing a rounded-shape model. It needs to be bent (and smooth curve), sanded and glossy painted.
At first I wanted to use a 1.6mm aluminium sheet but felt that bending it and making it into a "round" would be difficult. The diameter of the circle (outer layer) would be anywhere between 18-20" (still haven't decided but it will be under 20"). Then I thought of styrofoam. After some searching on the net I saw that "extruded-type" foam would be a good material. There needs to be a space inside of about 15 sq.inches or diameter to accommodate some stuff inside. To do this I'll need to use alu sheet (<1.6mm) and some light frames to support the weight of the things to be kept inside. Think of it as a styrofoam-coated almirah without the doors. So the material needs to be strong.
Can you guys suggest me some stores in New Delhi from where I can get this material and price.

Query 2. How do I stick two thick styrofoam together so that I can use it as a single super-thick styrofoam block? I think its called Lamination or something. I know paper lamination but not styrofoam lamination. Where can i get this done?

Query 3. What is the proper/best way of molding styrofoam and 3mm acrylic sheet? I'll also need to bend the acrylic sheet into my desired curvy shape.

Query 4. I need the material to be painted. Is there any way i can give glossy-paint to a styrofoam? Where can i find this "KRYLON H2o Latex Spray Paint"?
Source: http://www.ebay.com/gds/How-to-Paint-Styrofoam-or-builders-foam-craft-projects-/10000000000069259/g.html

Please reply asap!

@leDerp,
Try to locate something called a 'Forex' sheet. I got one 2'x3'x2mm. From a stationery supplier. Can be cut with scissors and easy to bend by hand. Glossy finish. About 10 times stronger than cardboard. Haven't tried, but looks like it would take spray paints.
If you give us some idea of what you are trying to make, many members will give you useful suggestions.

Quote from: K K Iyer on December 24, 2013, 05:44:18 PM
@leDerp,
Try to locate something called a 'Forex' sheet. I got one 2'x3'x2mm. .

2mm thickness? Way too thin. I need something which has a min thickness of about 1".
I want to build a custom rack.

Anyone?

can i use acrylic sheet at place of styrofoam

is there any shop for coroplast sheet in pune region