How to Cut and Join Polystyrene Mouldings

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Polystyrene Moulding
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step 1

You can use your power saw to cut polystyrene picture frames but you must replace the blade.

step 2

Blades with higher teeth (80 teeth or more) are recommended for wood mouldings, but this is too many teeth for cutting polystyrene frames.

step 3

For best results, replace your higher tooth blade with a 36 tooth blade to cut polystyrene frames.  This will reduce the heat the saw generates.

step 4

Too much heat can cause polystyrene frames to melt, so move the blade quickly through the moulding to avoid heat build up.

step 5

Polystyrene frames cut easily with no resistance.  After cutting, line up the mouldings side by side so the miters are flush and test for exact length.  If you need to sand, go ahead.  Polystyrene frames are easily sanded on a manual rotary sander.

step 6

Polystyrene frames are assembled with Plastibond Glue designed specifically for joining polystyrene frames.  Its a fast acting glue that bonds strongly, much like Super Glue.

step 7

Apply the glue to one of the miter faces.  Don't overdo it.  The bond is so strong that a little glue goes a long way and any glue that squeezes out at the joint can damage the surface ornamentation.

step 8

Press the two miters together to form a corner.  Try to move quickly from corner to corner as the glue dries quickly.

step 9

Lay your band clamp slack around the frame so that you will be ready to clamp as soon as the four corners are pressed together.

step 10

Turn the ratcheting device on your band clamp to close the joints tightly.

step 11

Leave your frame in the band clamp for five minutes.  The resulting joints are so strong that you will not need to nail the frame.  But if you want to drive V-nails at the joints, go ahead.  Polystyrene frames can take medium/soft V-nails.

step 12

Use the EZ-Finish Mounting Kit to mount the art, hold the contents in the frame, and attach the hanging hardware.