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Old 02-26-2013, 10:52 AM   #7 (permalink)
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Another option is to fiberglass first, then fill in with foam, then fiberglass over the top of the foam. If you fiberglass first, you can remove the fiberglass 'form' and then fill it with expanding foam. The form should be rigid enough to work with. I think if I was to redo my pretty prius grill block I'd go this way. The foam is hard to form and if you want to finish it nice that means lots of sanding and the foam eventually gets squished. If you do it this way, there is a hard backing that will prevent this.
Current project: Help me kill my alternator - it is stubborn and won't die
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