Styrofoam Scenery tip from: Bill Kamery
I have found using metal brushes to be a very effective method of forming styrofoam when constructing scenery.  I found a pair of brushes, resembling toothbrushes only 2-3X bigger, at the local hardware store -- one had stainless steel bristles and the other had brass and was less stiff. These worked great for "fine-tuning" the foam shapes after using a Surform tool for the rough shaping.

After getting the foam shaped, I mixed up a batch of "Durhan's Rock Hard Water Putty" (great name, huh?), mixing it much thinner than the directions called for and adding some water-based paint of the color I wanted.  I applied this over the foam using a sponge brush, popsicle sticks and my fingers, whatever seemed to work best. It dried okay, and provided a hard, thin and lightweight shell over the foam. 

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site updated: 02/17/08