Example of polyurethane foam car "sculpting"

[Keen]

I used a saw, and a surform. If it makes any difference, and I think it does. I used the spray foam "large areas" It seemed to cure much softer than the other stuff. It does expand much more though. I am thinking that on my next attempt I will fill the large areas with blocks of eps or xps foam, then fill in the gaps with spray foam. I was also thinking about building a lattice with very thin pieces of wood then draping fiberglass over that. Following that I would cover with bondo, and sand it down until parts of the lattice were exposed.

[Blue07CivicEX]

Those fog lamp holes are annoying, have you done any testing with them covered yet? I am doing a couple test runs next week until I can get my permanent covers made, anybody know where to get materials to glass over the foam? Home Depot have it?

[johnpr]

you can get bondo brand fiberglass materials from wal-mart, auto parts stores, and home depot., i havent tested yet but i dislike them so much that i really dont care how little of an improvement i see so long as it looks better

[Blue07CivicEX]

Johnpr, Also if you haven't already look under the rear bumper on the drivers side there is a HUGE parachute under there which would be do well to be covered up and became one of my priorities when I saw it.

[johnpr]

yep i saw that also, i have been debating on how i want to tackle that area. if i have time i will take measurements and that will help me decide on a material. have you thought about how you will mount a panel near the rear axle, i was thinking about welding some tabs on there. i will take some pics though and figure something out

[Keen]

I've noticed that parachute as well. That is going to be the next project after the grill block. Were you guys thinking of using pour foam to fill it in?

[johnpr]

not in the rear, i think with that amount of foam it would be a considerable amount of weight, i am either going to use a plastic or metal sheet, whichever is cheeper for me.

[Blue07CivicEX]

I am going to look into getting a sheet of coroplast for that sheet and test it out, there aren't any high temp parts in the area so anything that can withstand some rock hits would work well.

[3wheeled]

My kids and I have been building a 3-wheel car from the ground up. We have built the body out of urethane boards purchased from a local lumber yard. Glued the panels together with the spray urethane foam (Home Depot) and then covered both sides of the body with 2 layers of fiberglass and polyester resin. It is quite a job but a lot of fun for sure! Here are some pictures over the years...

http://picasaweb.google.com/stinger3wheel/Stinger

[TheDon]

Originally Posted by MetroMPG

Many more pics:
http://englishrussia.com/?p=1949

those are some massive wheels