I'm not really sure what you're asking about the foam. There are 6 pieces total, all the same size as the bottom ones. I cut the insulation in half lengthwise, it goes in enough to hold it securely (would depend on the size of your insulation, though).
Haha, that curve actually looks terrible. It only looks good in the picture because of the low resolution and the shadow+black paint. I used my cardboard block as a template and had to make a couple slight modifications (the coroplast isn't as flexible as the edges of the cardboard were). I cut everything out with a utility knife.
Took some ninja-ing to get the zipties routed, though.
I'm going to see about replacing the stock belly pan that is between the bumper and engine with a coroplast one that doesn't hang down as far. I just keep forgetting to feel how much heat is radiating from the exhaust after a long drive so I can see how far back I can take it without risking melting.
I get comments from gate security all the time about my sweet wheel covers.
