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Old 07-08-2008, 10:25 AM   #55 (permalink)
MetroMPG
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Join Date: Nov 2007
Location: 1000 Islands, Ontario, Canada
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Blackfly - '98 Metro
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Well, the foam did cure stiffer than when I last checked last night, but it's still somewhat spongy. I was a little disappointed. Not ideal, but workable. Also, the expansion caused the foam to lift the "leading" edges where it meets the hatchback (the "C" pillar area).

I was able to carve/shape the contours I wanted using a bread knife for the roughing in, a hand held hacksaw blade used as a rasp for finer shaping, and some coarse sandpaper on a sanding block. But it's going to take a lot of "finishing" work with body filler & spot compound to get it smooth & looking nice after the glass is laid over top.

I'll do the other side this evening, and post up some pics. I'll lay up the first layer of fiberglass tomorrow.
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