Expanding Foam body sculpting

[freebeard]

Well at least we know it involves "mixing up product".

If I were faced with having to do that, I would mix two different sizes of micro-bead foam (insulation or something) in polyester resin, wrap one panel at a time with Mylar foil and squeegee the resin out underneath it. Then peal off the Mylar and prime and sand and prime and sand...

[Big time]

Originally Posted by ldjessee00

Hello,

I would never have thought to use this much expanding foam, but it seems to have worked for this guy!

This Guy Dumps Weird Goo All Over His Car...

This seems that it could be used to change the shape (and aerodynamics) more dramatically than I would have thought possible using expanding foam.

LDJ

It is amazing how eye catching big wheels are even if they are not the best for aerodynamics.

I think that the overuse of expanding foam would make it very safe in a crash.

Good looking car though.

[Xist]

How does great stuff hold up with vibrations over time?

[Cobb]

I think its all show and no go. I know guys who try to drive daily on those big rims on the impalas, crown vics and such. They spend 25 bucks a week in wheel studs as they are always breaking them if not a pot hole and bending a rim.

[botsapper]

Wanna a custom grill block, add custom spats or even a permanent boat tail? After you form your plug pour/spray you expanding foam, cut you new tail, sand down to shape...

https://www.youtube.com/watch?v=owFuQVSZLR0

Follow the rest of this guy's detailed video posts.

[deejaaa]

thought about this but enclosing all the exposed foam to avoid water absorbtion.

[Varn]

I have used expanding foam to rebuild rocker panels. After 2 years they still have not fallen off/out.

[kach22i]

Originally Posted by Varn

I have used expanding foam to rebuild rocker panels. After 2 years they still have not fallen off/out.

I did something similar five years ago, and at the time was convinced it would hold moisture and rot out first. I was wrong, it's now the one spot not taken out by rust.

Five years ago: Opened corner up (fist sized hole) and filled the cavity w/foam.
S10 4x4 Pick Up Photos by kach22i | Photobucket


Today:


Now the non-foam treated side is a bit more interesting, that side was fine five years ago, so it was never opened up.

Five years ago:


Now/today:


From this documentation, one might argue that the foam holds less moisture than dirt inside of the panels, or moisture locked in because of possibly clogged weep holes.

Therefore foam is superior, but that might not be the whole picture.

In general, my driver's side is twice as rusty as the passenger's side.

I suspect this is because that when parked on the street in front of my house, the driver's side faces the street where the spray of salt in the winter is being kicked up by passing cars during the winter months.

Looks like I might have to foam my whole truck, but if I do that shouldn't it be more aerodynamic this time around?

[Otto]

Polyurethane foam such as Great Stuff is closed-cell, and adheres very well, so is used for flotation in boats. Gorilla Glue is also polyurethane, so makes a good adhesive for PU foam board. Sculpting PU is said to be better than polystyrene because you can use polyester resin, less expensive than epoxy. And PU foam is said to be easier to sculpt than polystyrene.

OTOH, you can hotwire cut polystyrene, but not polyurethane.

[freebeard]

So your saying that with this 99¢ tool I got at Goodwiil—and more patience than I could ever muster—I could reproduce CarBEN?



That is some scary schtuff.