I have posted this on another site, but I think it is good information on the coroplast decoys. I had many questions on how to make them, so I read up quite a bit and gave it the old college try (I am a few years out of college...almost 15 years to be exact). I purchased my coroplast at Midland Plastics in Madison, WI. Here is the report I made up....enjoy....
Homemade Goose Silhouette Decoys
Webshot Photos:
http://community.webshots.com/album/553351392SZLqGv
Introduction:
I read quite a bit about homemade silos on this and other websites. I decided to make them this summer to get my buddies off my back. I told them I would make them last year, but never got to it. I decide to go the coroplast route, mainly for the weight. Most of the fields I get to hunt are 'walk in' fields. I decided to make 5 dozen for starters. There were two things that I could not get really good answers to on any websites.
1. How much do the homemade coroplast decoys cost? Websites state anywhere from $1 each to $3 each. I planned to keep a tab on the cost for future reference.
2. How durable will the decoys be? Websites say they last years and others say they are not durable at all. I will not be able to answer this question in the post, but they look good and the paint seems really tough.
Patterns and Templates:
A buddy gave me some sample silos to use for patterns. I cut the pattern out of cardboard and sketched in where I wanted each paint color to go. Next, I created construction paper templates for painting the decoys. I made two painting templates for each color of each style of decoy. This makes it easy to paint both sides of the decoy without carrying over paint (if you tried to flip the template over for the other side).
Cutting Them Out:
I bolted the 5 sheets of coroplast together. I positioned the templates on the sheets of coroplast so the channels in the material ran vertically through the decoys. The bolts were placed somewhat close pattern to be cut out. I used a Rotozip to cut the decoys out. 1 cut = 5 decoys. Cutting went pretty quick. There was some problem with the plastic melting at times. I believe this may have been due to a dull bit or incorrect cutting direction on my part. The melted areas and rough edges cleaned up relatively easy with a utility knife.
Stakes:
There seemed to be a lot of opinions on the websites about stakes for the decoys. I have read to use fence wire, flat stock, welding rods, and other items. I did some searching and found that 3/16" cold rolled steel round stock worked quite well. It fit snug in the 4 mm coroplast holes and was relatively cheap. I found the round stock at a local supply company for $0.17 per linear foot. I cut an 18" section for each decoy. I rounded one end and put a slight point on the other end of each rod. I put a small amount of Elmer's Pro Bond glue in one of the vertical channels in the coroplast. I pushed the rounded end of the rod up into the glue. I pushed the rod in so there was about 10" left outside the decoy. This glue bonds GREAT, but it does expand as it dries. I set the rods and left them stand in the garage over night. When the glue was dry the next day, I cut off the glue that had drizzled down the rod.
Paint:
My under-estimation on this job was definitely the painting process. I decided to go with a 4 color decoys (brown, black, white, and gray). In an effort to reduce paint problem, I decided to use the Krylon Fusion and Rustoleum paints for plastics. They run about $1 per can more than normal paint...I am hoping it is worth the extra money. Krylon has Fusion Camo paints that are 'ultra flat' (I used the brown and black). I used white and gray (flat) primer made by Rustoleum. White is made for plastics. Gray is not made for plastics, but was sprayed over the white base coat. I started with brown and painted only areas that needed to be painted brown (trying to reduce the paint usage). Once the brown paint dried, I used the black stencils and painted the black areas. Once the black paint dried, I used the white stencil painted in the white areas. I then followed with some gray in the chest areas of the decoys. Two observations were that it took a lot of paint and a lot of time to paint the decoys (the way I wanted to).
What I Would Do Differently Next Time:
When cutting out the decoys, I would limit it to three sheets at a time versus 5 sheets. I think it would help reduce melting and subsequent clean-up.
I would make the painting templates out of something stiffer than construction paper. The construction paper started warping due to the paint that dried on it. When the templates warp, they allow overspray onto area that you have just painted.
I will see how the stakes hold in the ground. I am a little concerned that they may turn too easy in a stiff wind. This would be the same for almost any round stock that could have been used. If there is a spinning problem, I may add another small rod or make a bend in the rod that is already in the decoy. I know some movement is okay, but I don't want all of them pointing one direction at the end of the day.
It would be a lot cheaper and quicker if the brown base coat could be rolled onto the decoys. I could not find any 'ultra flat' paint for plastic in a quart or gallon.
Costs:
5 sheets of Coroplast @ $11.00 per sheet $55.00
90' of 3/16" CRS Rod @ $0.17 per foot $15.30
9 Cans of Krylon Camo Ultra Flat Brown Fusion Paint @ $3.97 per can $35.73
6 Cans of Krylon Camo Ultra Flat Black Fusion Paint @ $3.97 per can $23.82
4 Cans of Rustoleum Flat White Primer for Plastics @ $3.97 per can $15.88
2 Cans of Krylon Flat Gray Primer @ $2.97 per can $ 5.94
Subtotal: $151.73
Tax @ 5.5% $ 8.35
Total Cost for 60 Decoys $160.08
Cost Per Decoy $2.67 Each
SUMMARY:
The decoys were quite a bit more expensive than I was planning. The biggest cost driver was paint, which I had over $80 invested. I think they look pretty decent for a first try. My hunting buddies also seemed pretty impressed. I would love any comments and suggestions you have. I hope this helps others that are thinking about making coroplast decoys. It definitely took more time and money than I was expecting…hopefully it is all worth it this fall.
Take Care,
Paulie