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Originally Posted by mikesheiman
Far as the fill-in (actual fabrication), any recommendations on how to achieve that (materials, tools, method) without it looking like a really crude hack job and having to mess with redoing the fiberglass? I figure that's something I could knock out quickly given the right method, unlike the rear section redo.
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This is what I did, and it lasted.........but some will cringe.
Bodywork on S10 Pick Up - Epoxy - Pelican Parts Technical BBS
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Cab hole; This was repaired once before, opened it up and not a lot left to work with. I took a can of spray foam and let it form a backer (despite knowing that it may absorb moisture over time). I chopped up some fiberglass strands and epoxied them, using plastic wrap and tape to defeat gravity.
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I'm thinking you could glue on some foam or spay foam on and shave off the excess, then glass it up.
My repair using foam lasted longer than the non-foam side, so my worries about the foam holding moisture turned out to be unwarranted.