Have surfed yahoo/boardbuilding trying to figure out how to use ABS for rails.

I wants to make it a oneshot process.
I know that i have to grind them and flame them to make a better bond.

but how do I get them to be firmly fixed to the foam?
Read somewhere that I should route a hole to the abs in the foam, but this I don't get wont it expose some foam?

I epoxy the ABS on first. Doing it all in one shot would be very hard to get good results, too difficult to keep everything in place and tight. There probably is a way to do it but odds are you will mess something up

If you made a mold I could see one shotting

my 2 cents
Mike S

Where do you Buy ABS in the US?

Vega the way we do our ABS railsand Hi impact polystyrene is in one shot .Buy a sheet its cheap ,cut out the middle with enough flash trim .Trim core to go inside of Abs gasket .5mm wide rails should be ok depending on the thickness of the abs being used .Trim core edge to suit.Then vacuum in one hit .When done debag and trim rails. If you do rails seperatly its impossible and not accurate.Plus its a lot of work. Make big gasket.To prep Abs simply sand it .Go to any plastic shop or distributor.So undercut for core and overcut for rail profile when making one piece gasket for rails.