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scotty b
post Jan 5 2011, 03:17 PM
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I have to make a custom bumper for a car. I am familiar with the mold process but what I do not know is what type of expandable foam I should buy. I am planning to make a wooden box ( form) to pour the foam in, then attatch it to the car and start cutting and sanding to get the desired shape. What I need is something that will expand and still be closed cell enough to handle cutting, sanding and shaping, then can handle bondo being applied to get that oh so smooth ready to be painted, finished buck. (IMG:style_emoticons/default/wacko.gif)
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underthetire
post Jan 5 2011, 03:38 PM
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Tap plastics used to sell a resin foam, it was pretty tough stuff, but a little on the heavy side. My project cam out like sh*t but thats just me.
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Rod
post Jan 5 2011, 03:53 PM
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Use polyurethane two-part foam, The foam from diy shops is rubbish for your purpose - it leaves big holes as it expands.
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jd74914
post Jan 5 2011, 04:16 PM
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(IMG:style_emoticons/default/agree.gif)

I don't have much experience, but if you want to pour foam, use a 2lb poly foam. To let it cure nicely and keep from being super porous, you probably will want to pour in multiple stages.

It might be easier to used closed cell insulation-type foam from Home Depot or Lowes (the blue is typically used), and form with a hot knife and then belt sander.
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iamchappy
post Jan 5 2011, 04:30 PM
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Have you considered using Styrofoam and shaping it instead of a using a mold.
I have done things this way as well as it is the standard for making fiberglass surf and sailboards.

Just throwing it out there....
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URY914
post Jan 5 2011, 05:09 PM
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Try looking at some of the projects on here.....

http://www.fiberglassforums.com/

I'm a member to this forum and they have some good folks that can help you out.
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RJMII
post Jan 5 2011, 05:12 PM
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This place seems to have a lot of information. I did a bunch of reading there a few years ago, but haven't been able to put anything into practice yet.

http://www.fiberlay.com/

edit:

The expandable foam link is on the left, couldn't get a good link directly to where I was trying to show you.
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Mike Bellis
post Jan 5 2011, 05:14 PM
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Order some surf board blanks (IMG:style_emoticons/default/aktion035.gif)

There's surf shops all over on the Left Coast (IMG:style_emoticons/default/smoke.gif)
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URY914
post Jan 5 2011, 05:55 PM
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I see the pink insulation boards that you can get at Home Depot being used a lot. I plan on using them when I make a new piece for my car.
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stepuptotheMike
post Jan 5 2011, 06:16 PM
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One of the shows I saw on TV used sheets of florist foam...they laminated sheets of it together with gorilla glue to get the thickness needed and then shaved it down to shape. They were making fender flares.

Mike
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URY914
post Jan 5 2011, 06:18 PM
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The spray on foam seems to be used also...


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r_towle
post Jan 5 2011, 07:16 PM
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Scotty,

Use the simple spray foam and cover it entirely with plaster or paris.
the plaster will not degrade with the fiberglass epoxy.
Use the plaster like bondo.
Rich
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mepstein
post Jan 5 2011, 08:23 PM
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comes in 914 colors


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PlaysWithCars
post Jan 5 2011, 08:44 PM
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Use the pink stuff from Home Depot. You can rough the shape in with a course wood file, then finish sand to shape w/ 80 grit sandpaper. But, you need to cover it with something before laying fiberglass over it, the resin will melt the foam.

I just used it over the holiday to make a mold for my "GT" seat project. Worked great and now I have two 914 seat shells w/ extended bolsters. (IMG:style_emoticons/default/cheer.gif) Next step is to learn how to do upholstery.

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Dr Evil
post Jan 5 2011, 09:07 PM
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I have used the spray foam. Cheap and easy, oh ya (IMG:style_emoticons/default/sheeplove.gif)
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scotty b
post Jan 5 2011, 09:08 PM
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The sheets and particularly spray foam just isn;t going to cut it. I'm talking about a whole front bumper. That stuff may be great for a small project or a home doer, butI have to keep this within a reasonable budget. Surfboard blanks crossed my mind but the amount I would need would be $$$$ plus shipping got to be even more $$$$$$. I am looking for expandables because they are smaller to ship, they will fill a large box fairly quick and easily, and it looks so cool when it starts to grow (IMG:style_emoticons/default/smoke.gif) I'll check out the sites Paul and Jim posted (IMG:style_emoticons/default/smile.gif) Mike, I hadn;t thought about florist foam, I know I can get that locally in large chunks but will it hold up to the ibeglass resin ? A lot of foams will disolve. I will be making a female mold off of the buck, but will keep the buck just in case. If this turns out well I am going to try and sell them. Under wraps for now so dont ax (IMG:style_emoticons/default/shades.gif) not for a 914 though, but it is in la familia (IMG:style_emoticons/default/smile.gif)
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Dr Evil
post Jan 5 2011, 09:29 PM
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Shhhh

Yer phone is broke (IMG:style_emoticons/default/dry.gif)
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URY914
post Jan 5 2011, 09:41 PM
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Yes the green foam used by the flower folks will not get eaten by the resin. I just used some today. (IMG:style_emoticons/default/biggrin.gif)
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Phoenix-MN
post Jan 5 2011, 10:02 PM
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This place has all the "glassing" supplies you'll ever need.
http://www.cstsales.com/
I used thier Rohacell foam when I had to modify my front bumper. The stuff is a little spendy but works very well.

Paul
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stepuptotheMike
post Jan 5 2011, 10:26 PM
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(IMG:style_emoticons/default/sunglasses.gif)--><div class='quotetop'>QUOTE(scotty b @ Jan 5 2011, 10:08 PM) *</div><div class='quotemain'><!--quotec-->
The sheets and particularly spray foam just isn;t going to cut it. I'm talking about a whole front bumper. That stuff may be great for a small project or a home doer, butI have to keep this within a reasonable budget. Surfboard blanks crossed my mind but the amount I would need would be $$$$ plus shipping got to be even more $$$$$$. I am looking for expandables because they are smaller to ship, they will fill a large box fairly quick and easily, and it looks so cool when it starts to grow (IMG:style_emoticons/default/smoke.gif) I'll check out the sites Paul and Jim posted (IMG:style_emoticons/default/smile.gif) Mike, I hadn;t thought about florist foam, I know I can get that locally in large chunks but will it hold up to the ibeglass resin ? A lot of foams will disolve. I will be making a female mold off of the buck, but will keep the buck just in case. If this turns out well I am going to try and sell them. Under wraps for now so dont ax (IMG:style_emoticons/default/shades.gif) not for a 914 though, but it is in la familia (IMG:style_emoticons/default/smile.gif)
[/quote]

Worse comes to worse.... cover it in aluminum foil. Then glass over it to make your mold. I've never personally used it... but that's how they did it on the TV episode.... I think it was the show Musclecar on SpikeTV.

Mike
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