Where to buy Interior Fab Stuff?

[chris556452]

If your looking for complex curves then I suggest expandable foam under the closed cell foam. You can create some great natural looking shapes with the foam. Just clamp down the areas that are not to be expanded. I did this for the rear parcel shelf in my corolla. Clamped down the area where two 6x9s were going and clamped down a flat area between them. Then I sprayed the foam in the rest. Turned out great.

 

Garvice, this sounds interesting is there any way you could post up some photos to get a reference?

Thanks,

Chris

[garvice]

Chris,

Here are some photos of the parcel tray 9 years and 200 000 kms after completion (I.E. It has taken quite a beating in that time, so that's why it doesn't look the best). Bit hard to see the curves in the photos, it looks much curvier in person.

 

I started with a 3mm MDF board with holes cut for the speakers. Stapled the foam to the MDF, screwed the speaker grille on top of the foam where I wanted the speaker to go. Screwed a piece of MDF in the middle of the parcel shelf (where you see the indentation) and then squirted the expandable foam under the closed cell foam. Actually to tell the truth it wasn't even closed cell foam, it was just that white light density foam.

 

Just squirted as was required to get the shape. Left to dry, then removed the grilles and MDF cutout in the middle and covered with carpet. Dead easy, just takes some patience. If you put to much foam in, you can make a hole while it is wet and push the foam around, although be careful as it is very sticky and really only comes off while wet. Also when it is hard you could probably sand it and fiberglass it if you want it rock solid.

 

[chris556452]

Garvice,

Thats pretty cool man, thanks for the photos. It makes it look more OEM with the aftermarket speakers without the whole glossy fiberglass thing goin on