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Thread: Progress on door panels and rear side panels

  1. #31
    Registered Member chevynut's Avatar
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    Paul, in case you're interested here's a little more on the pour foam....

    http://www.trifivechevys.com/showthr...on-side-panels
    56 Nomad, Ramjet 502, Viper 6-speed T56, C4 Corvette front and rear suspension


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  2. #32
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    What I was thinking about was not "pour foam" but sculpted rigid foam, acquired in sheets of various thickness.

    Not sure the difference in available rigidity, but I think the sheets may be available more rigid.

  3. #33
    Registered Member chevynut's Avatar
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    Rick, I don't know what kind of foam you're thinking about but I think pretty much any "rigid" foam is going to dent or break. I have also explained before the difficulty in attaching flat sheets of foam to these door panels that are NOT flat. They have many compound curves and that's why I used pour foam.

    I wonder if some of the semi-rigid foam like "ethafoam" would work. I think it's closed-cell polyethylene and it's harder than open-cell foam. I just think it would be pretty difficult to shape. This pour foam (urethane) is easy to shape and smooth. The spray foam insulation I tried isn't recommended, as it's too "rubbery" to shape easily.
    Last edited by chevynut; 08-31-2015 at 08:16 PM.
    56 Nomad, Ramjet 502, Viper 6-speed T56, C4 Corvette front and rear suspension


    Other vehicles:

    56 Chevy 2-door BelAir sedan
    56 Chevy 210 4-door sedan
    57 Chevy 210 4-door sedan
    1962 327/340HP Corvette
    1961 Willys CJ3B Jeep
    2001 Porsche Boxster S
    2003 Chevy Silverado 2500 HD Duramax
    2019 GMC Sierra Denali Duramax

  4. #34
    Registered Member Fladiver64's Avatar
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    I have used some of the more rigid foams in aircraft construction and the 18 lb per cf is very dense and would stand up to a fair amount of abuse. We used it to make structural blukheads in aircraft with a fiberglass layup on both sides. You could probably get away with just covering with interior materials or even just a coat of resin. Lazslo brings up a good point about attaching to compound curves, you could mix up a paste of micro balloons and resin like a putty to make up the difference depending on the gap and final structural integrity needed.

    http://www.aircraftspruce.com/catalo.../lastafoam.php

  5. #35
    Registered Member chevynut's Avatar
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    Wow Mike, 18 pcf? That's some heavy stuff. The foam I'm using is 2 pcf.

    http://www.trifivechevys.com/showthr...highlight=pour

    I do have some micro-balloons an I've used them with the polyester resin as a filler were I had large bubbles in the spray foam. It works pretty well and I guess it might help fill the gaps between foam sheets and the panels. I'll try to take a pic of the backside of a door panel so you can see how curved they really are. The rear side panels aren't quite as complex, but they still have some significant curves and bends.
    56 Nomad, Ramjet 502, Viper 6-speed T56, C4 Corvette front and rear suspension


    Other vehicles:

    56 Chevy 2-door BelAir sedan
    56 Chevy 210 4-door sedan
    57 Chevy 210 4-door sedan
    1962 327/340HP Corvette
    1961 Willys CJ3B Jeep
    2001 Porsche Boxster S
    2003 Chevy Silverado 2500 HD Duramax
    2019 GMC Sierra Denali Duramax

  6. #36
    Registered Member chevynut's Avatar
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    Got a little more done the past couple of days. I pretty much finished the upper sections except for a little touch-up with the polyester and got started on the next removable sections. I also had to re-shape these panels 1/4" below the finished surface. Notice I also used some spray foam on those and they ended up with some big bubbles but they'll still work. After those are done, the rest should be easy.




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    56 Nomad, Ramjet 502, Viper 6-speed T56, C4 Corvette front and rear suspension


    Other vehicles:

    56 Chevy 2-door BelAir sedan
    56 Chevy 210 4-door sedan
    57 Chevy 210 4-door sedan
    1962 327/340HP Corvette
    1961 Willys CJ3B Jeep
    2001 Porsche Boxster S
    2003 Chevy Silverado 2500 HD Duramax
    2019 GMC Sierra Denali Duramax

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