started on my fog light cover/insert/delete today
this is stage 1, revision 2.0
revision 1.0 didnt work out quite how I expected, however I can save them if rev 2.0 doesnt work.
rev 1.0 was just putting my foil liner in, then filling the entire thing with expanding foam, which it did... a LOT, making them basically 2 times larger than where they are going to be placed, but that isnt such a bad thing as I can always trim down to fit it 2.0 doesnt work.
rev 2.0 is going to be 3-5 stages
stage 1 is the foil lined mold, with a coroplast brace in to help keep its form in the mold. the foil was tucked just a little behind the actual fog lamps, but not enough to catch when removed, more along the lines to help brace it once its all finished. in the image, you can see the forming, the brace and the foil lining.
basically just the inside outline here.
stage 2 will consist of filling in most of the center, but not fully, allowing some extra room for expansion of the foam. if the foam expands enough, I might be able to skip stage 3 and move to stage 4.
stage 4/3 will be bringing the foam out just past the edges to allow for trimming/smoothing, and filling in any possible gaps that may accrue from the expansion.
the final stage will just be covering the foam with a piece of coro or lexan (havent decided) and attaching holes/screws/clips to hold it in.
anyways, the foam Im using has a 24hr cure time, so I dont know how much more I will accomplish today, it really depends on both the cure time for such a small amount and the weather (have a t-storm coming in right now...)
so its going to be
going for the final