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Old 02-26-2013, 11:52 AM   #7 (permalink)
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Join Date: Dec 2007
Location: Germantown, WI
Posts: 11,023

CM400E - '81 Honda CM400E
90 day: 58.68 mpg (US)

Daox's Grey Prius - '04 Toyota Prius
Team Toyota
90 day: 49.53 mpg (US)

Daox's Insight - '00 Honda Insight
90 day: 64.33 mpg (US)

Swarthy - '14 Mitsubishi Mirage DE
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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: Adding regenerative braking to the Mirage
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