How to Compound Neoprene Rubber

You can compound multiple sheets of neoprene rubber to form thick, durable seats and pads that increase comfort and safety for a variety of activities. Neoprene is the black or gray synthetic rubber foam that is commonly used in wet suits and flexible leg and ankle braces. Gluing stacks of neoprene sheets together creates a substantial foam rubber pad to enhance cushioning and give the user extra layers of protection.

Things You'll Need

  • Paper
  • Pencil
  • Scissors
  • Neoprene rubber (1/8 or 1/4-inch)
  • Razor blade knife
  • Acetone (nail polish remover)
  • Shop towel
  • Wide natural bristle paintbrush
  • Neoprene cement
  • Neoprene fabric (optional)
  • Plywood boards
  • Spring clamps
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Instructions

    • 1

      Trace or sketch the design for the neoprene cushion that you want to construct. Drawing the item slightly larger than you need will allow you to cut away excess neoprene at the end for a snug fit.

    • 2

      Cut the design out of the paper and lay it on a sheet of neoprene foam. The base layers of the cushion will adhere to one another better if you use foam without nylon fabric backing.

    • 3

      Cut around the paper pattern with a razor blade knife before moving the pattern to cut additional pieces of neoprene foam with the same dimensions. Stack the cut pieces on top of one another to see if you have cut enough pieces to achieve the desired thickness. Test the stacked pieces by sitting or kneeling on them to determine the level of cushioning.

    • 4

      Separate the cut pieces of neoprene and wipe down all their surfaces with acetone cleaner. The cleaner prepares the neoprene for the adhesive by removing dust and oils from the surface.

    • 5

      Apply a thin coat of neoprene cement to the clean and dry top surface of one out of every two of the cut out pieces using a wide paint brush. The wide brush will allow you to work quickly and cover the entire surface evenly in just a few seconds.

    • 6

      Flip the cleaned surface of the neoprene pieces over onto the cement-covered neoprene and align their edges as much as possible.

    • 7

      Wipe down the top of every neoprene foam "sandwich" you have created with the acetone-soaked shop towel and allow them to dry.

    • 8

      Apply a thin layer of the neoprene cement to the top surface of half of the stacks of foam. Continue stacking each glue-coated surface to an acetone-cleaned surface until the desired thickness is achieved. Glue on a single layer of nylon fabric-coated neoprene to the very top of the stack to protect the pad from wear.

    • 9

      Place the compound neoprene in between two pieces of plywood that are larger than the pad. Secure the neoprene by applying spring clamps around the edge of the plywood sheets.

    • 10

      Allow the neoprene cement to dry according to the directions on the label before removing the clamps. Most neoprene cements are dry within 10 minutes.