2013 Subaru Impreza WRX STI - Project Log

[jedi_sol]

Originally Posted by Xist

Funny story: My Great Foam is seriously stuck to the aluminum foil.

oooh is that what you meant? yes, the great foam sticks to the foil. The important thing is that the foil is removable from the car.

So essentially you have a foil-backed-foam-plug.

makes sense?

[Xist]

Originally Posted by jedi_sol

oooh is that what you meant? yes, the great foam sticks to the foil. The important thing is that the foil is removable from the car.

So essentially you have a foil-backed-foam-plug.

makes sense?

That was what I wanted?

[jedi_sol]

Making slow progress on grill block v3.1 because I only have 2 hours a day to work on it.

Fiberglass has set...it's a little uneven as the resin gets absorbed by the great foam. Good thing is that the Great foam has not shrunk yet


Bondo


Guide coat to help make the bondo as even as possible


next up this weekend: Sanding, bondo, sanding, bondo...hopefully paint.

[Xist]

Looking good! Do you use peel-ply (or "Polyester Taffeta")? I found some nice tricks in: http://ecomodder.com/forum/showthrea...yup-20811.html

[jedi_sol]

Originally Posted by Xist

Looking good! Do you use peel-ply (or "Polyester Taffeta")? I found some nice tricks in: http://ecomodder.com/forum/showthrea...yup-20811.html

Yes i tried that!

The TOP of the fiberglass came out smooth, however, because the greatfoam absorbed the resin unevenly, the bottom became uneven.

so i've got smooth and uneven fiberglass. oh well

at least i only had to use a thin layer of bondo, so sanding shouldnt be that bad.

[Xist]

Originally Posted by jedi_sol

Yes i tried that!

The TOP of the fiberglass came out smooth, however, because the greatfoam absorbed the resin unevenly, the bottom became uneven.

so i've got smooth and uneven fiberglass. oh well

at least i only had to use a thin layer of bondo, so sanding shouldnt be that bad.

Did the 'Stuff absorb the resin, or did the resin melt the foam?

Is there a difference?

I guess that I cannot say that I have not done anything, I went through one can, but I am going to study instead of continuing the process.

No, really! I mean it this time!

I did a quick search because I remembered that there were different types of resin and foam and that some work together and others do not. I remember someone putting resin on his foam and it melted the outside a quarter-inch or so. Anyway, have you read this? http://ecomodder.com/forum/showthrea...oam-21668.html

[Xist]

So, I was actually studying (!) and I thought of something.

Do you think that Great Stuff would absorb through fiberglass mat? Obviously not, if you put resin on it and allowed it to cure, but I was trying to think of something better than my foil-backed foam, something workable.

My other thought was, have you ever opened a package and there was a protective sheet of really-thin foam? What if I took a sheet of that, lined my fog light socket with it, and then sprayed foam? The two types of foam would bond and then I could work that, if I needed to.

Maybe this?

Staples Anti-Static Air Foam Dispenser Packs, 175' | Staples®


This place has them cheaper, although I do not know about shipping and handling: http://trisupplies.shoppkg.com/shop/C2285.aspx

Those sheets are 12 or 24" across.

What do you think?

[UltArc]

Originally Posted by Xist

So, I was actually studying (!) and I thought of something.

Do you think that Great Stuff would absorb through fiberglass mat? Obviously not, if you put resin on it and allowed it to cure, but I was trying to think of something better than my foil-backed foam, something workable.

My other thought was, have you ever opened a package and there was a protective sheet of really-thin foam? What if I took a sheet of that, lined my fog light socket with it, and then sprayed foam? The two types of foam would bond and then I could work that, if I needed to.

Maybe this?

Staples Anti-Static Air Foam Dispenser Packs, 175' | Staples®


This place has them cheaper, although I do not know about shipping and handling: Anti-Static Air Foam Dispenser Packs at TriSupplies

Those sheets are 12 or 24" across.

What do you think?

That seems like a good idea. I would only be concerned about making a good seal, and the foam not breaking through. When I used Great Stuff on my GT front end, with (what I thought was) a good protection set, it broke through the news paper layer and foil layer and tape. It was rather difficult to clean up.

[Xist]

Originally Posted by UltArc

That seems like a good idea. I would only be concerned about making a good seal, and the foam not breaking through. When I used Great Stuff on my GT front end, with (what I thought was) a good protection set, it broke through the news paper layer and foil layer and tape. It was rather difficult to clean up.

You had newspaper- and foil-backed modifications?

You used one sheet of newspaper? Were you able to use one piece of foil or did you need to make it overlap?

Honestly, I would have thought three levels of protection would have been overkill. I am sorry that you learned otherwise!

Do you think that wax would work as a release agent with Great Stuff like it would with fiberglass resin?

With the way that my fog light plug project went, I was ready to purchase a small foam board and cut it to fit, but the spray foam worked out better than I had expected.

[UltArc]

Originally Posted by Xist

You had newspaper- and foil-backed modifications?

You used one sheet of newspaper? Were you able to use one piece of foil or did you need to make it overlap?

Honestly, I would have thought three levels of protection would have been overkill. I am sorry that you learned otherwise!

Do you think that wax would work as a release agent with Great Stuff like it would with fiberglass resin?

With the way that my fog light plug project went, I was ready to purchase a small foam board and cut it to fit, but the spray foam worked out better than I had expected.

I lined it with newspaper and painters tape, taped the paper into place, filling the lower grille, then taping the sides and ends down. I then did the same with foil. This was painters tape.

I couldn't say what failed, but the whole thing was just a mess. I am currently working with the foam carefully, and it is alright for filling the gaps my mirrors made.

I think the biggest mistake was to use a lot of foam at once, and fill the openings. I am being much more sparing now, and it seems like it is alright.