I thought I'd try to keep moving on my interior so I started pouring the urethane foam today. This is a lot harder than I thought it would be, and a lot harder than it looks in videos of the process. You have to mix the two parts in a cup, stir for 30 seconds, then pour it. It starts to foam up almost immediately, so it's hard to cover a large area with it.
I need to pour about a 1" thick layer on the removable panel that's attached to my rear side panel. I built a "dam" around the removable section with cardboard (drywall shims) and tape, and screwed it to the side panel. Then I mixed the foam and poured it. The area is about 6" wide and 30" long, and the foam increases about 30 times in volume. It's hard to get it spread out on that large of an area so I ended up doing two pours back to back, and it came out way thicker than I needed it. I tried it on both rear panels with the same results. Looks like the gallon of chemicals I bought isn't going to be enough.
Here's some pics showing the dams installed, and then after attaching it to the side panel, pouring and allowing it to rise.
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Next I have to remove the dams and shave the foam down some. After that I will pour the next section of the panel which is not removable, by putting another piece of cardboard along the edge of the removable piece. There is also another small rectangular removable section down lower that will get a little foam but that should be easy. Once I get everything poured, I will sculpt the final shape of the entire panel. In front I have two removable sections and three stationary sections to pour.
Once I get the sculpted shapes I want, I will cover the foam with polyester resin, then with fiberglass and resin. I need to compensate for the thickness of the fiberglass, soft foam sheet, and leather by making the foam smaller than the final size. My interior guy also says he wants .110" between the sections when finished and ready for leather.