I've used this method for a number of years and found that stapeling the foam piece works better than trying to hold it in a notch. This does two things. First, it allows you to tip out with the round portion of the foam rather than the edge, which keeps the foam bits from pulling off the edge, and secondly, the foam stays on the handle more securely.

Al Gunther

: If you cut a roller to make a tipping tool, hit the cut edge with the flame
: of a lighter or match. I had to remove a little piece of black foam from a
: fill coat after it cured. Melting the cut edge of the foam will melt any
: little pieces that might come off in your epoxy.

: I have used the standard wood-handled foam brushes for tipping with good
: results. Yes, they can start to tear a little bit if you apply a lot of
: pressure while tipping (they usually start separating at the base of the
: wood handle in the middle of the foam), but I've never had any pieces of
: foam come off the brush.

: Dean