Foam fill help.

John

Artisan
When I use a sander I try and keep the foam shavings. Then I make a glue and foam mix to fill these type of gaps. I will usually over fill, then use a heat knife/rod and melt the foam down a bit so that it has a move level and cohesive layer. Touch of sanding and you should be good.
You can also sand the parts. The mix of heat and sanding can fill gaps. I recommend trying this on a test piece first.
 
That is, generally, why I prefer blue camp pads over floor tile for most foam work. Smooth facings. That said, the floor tiles are fairly sandable, you should be able to de-texture them before gluing them up.
 
You can also use DAP rubber cement and carefully get it in there, than press the seems together to keep everything nice and tight together. The images didn't load for me so I am just blindly giving a suggestion. Also, if you are looking for a smoother overall weapon use high density EVA foam!
 
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