View Single Post
Old 11-28-2007, 08:20 AM   #1 (permalink)
MetroMPG
Batman Junior
 
MetroMPG's Avatar
 
Join Date: Nov 2007
Location: 1000 Islands, Ontario, Canada
Posts: 21,641

Blackfly - '98 Geo Metro
Team Metro
Last 3: 70.09 mpg (US)

MPGiata - '90 Mazda Miata
90 day: 53.78 mpg (US)

Winter beater Metro - '00 Chevrolet Metro
90 day: 61.98 mpg (US)

Fancy Metro - '14 Mitsubishi Mirage top spec
90 day: 58.72 mpg (US)

Even Fancier Metro - '14 Mitsubishi Mirage top spec
90 day: 66.29 mpg (US)
Thanks: 3,394
Thanked 6,201 Times in 3,212 Posts
Expanding, sprayable foam as an aero construction / shaping material

Had a thought recently after reading about the shaped foam board construction of an aerodynamic prototype which was used to make a mold. ... Ever since I made the Kardboard Kammback, I've been thinking about foam/fiberglass construction approaches.

I went up to the Home Depot and picked up an $8 pressurized can of high expansion urethane foam this evening.

"Cured foam dries rigid and can be shaped, sanded, trimmed, painted or stained."




Hmmm...

I'm going to try this stuff out making a couple of things on the car:

- shaped deflectors ahead of all 4 wheels/tires

- radiused transition at the aft edge of the front wheel arches (I've got lots of space between the arch and the tire to do this)

- possibly also boat-tailing behind the front wheels/tires

- this might make a good grill block plug material - custom fit! - though I've already got a "bra" on that does that job.

Tin foil taped/pressed in the area that will serve as the base of the object being created makes a decent non-reactive "release agent", and will protect the paint.

It'll be a bit of an experiment to see how well it adheres to vertical & upside-down surfaces, and whether I need to approach it in layers, or do it all at once.

Then of course the big issue will be discovering how nice or not it is to shape/smooth & what techniques work best.

__________________
Latest mods: 3-cylinder Mitsubishi Mirage. EcoMods now in progress...
Ecodriving test:
Manual vs. automatic transmission MPG showdown



EcoModder
has launched a forum for the efficient new Mitsubishi Mirage
www.MetroMPG.com - fuel efficiency info for Geo Metro owners
www.ForkenSwift.com - electric car conversion on a beer budget
  Reply With Quote