I want to make a replacment centre console out of fibreglass which will house a screen and relocate the aircon controls. the replacement console will go from the top little screen above the top aircon vents all the way down following the contours of the dash, and then towards the centre armrest compartment.

bla bla bla.

Basically im going to carve the basic blank shape out of Foam. Fibreglass over the top, then modify it to fit the screen, bla bla bla

The Block of foam i need is 800mm x 600mm x 400mm

Basically all im asking is what foam can i use that wont react to the resin and will be easy to carve ?

Whats it called and where do i get it and how much.

Many Thanks

I am not an expert on fiberglass, but if you want to get clean lines in the foam I am your man!

Just get a bit of toaster wire (normal wire just breaks), wrap the ends around two bits of wood and pass a nice current through it. When it gets hot it will carve the styrofoam like a hot knife through butter.

You can get toaster wire at ****smith/jaycar/toaster.

I am not an expert on fiberglass, but if you want to get clean lines in the foam I am your man!

Just get a bit of toaster wire (normal wire just breaks), wrap the ends around two bits of wood and pass a nice current through it. When it gets hot it will carve the styrofoam like a hot knife through butter.

You can get toaster wire at ****smith/jaycar/toaster.

you are one smart mutha clucker. i like your idea.. ill give it a shot when im at that stage.

A mate of mine that builds model aeroplanes uses the system to build the bodies... or something....

luke, u know clark rubber on the corner of sunnholt rd in blacktown... go there, they have the foam u need.. but the foam u want its pretty exxxy.

if u think the foam will be fked by the resin.. cover it in al foil ;)


else, if u wana be nifty.. buy some playdoh or clay.. chuck that in the console gap (perhaps line it with foil to stop clay getting everywhere on ur car). .. then mould the clay, then FG on that...

you always learn this AFTER your first attempt. at least u can save time by asking :P

edit* the foam u want, is in the back shelf of clarke rubber.. its blue.. and u can see the highdensity of the foam.. ask the guy there and he'll get it for u.. but like i said.. very exxy. They have a bunch of offcuts, but probobly not big enough for what u want.

i'm just about finished the same thing but i mounted the cd/dvd player where the ash tray/lighter use to be and a 7" screen is flush mounted where the old head unit use to be will post pics soon.

wouldent surfboard foam be the best bet?

wouldent surfboard foam be the best bet?


i was going to make a RC boat at one stage, so needed foam to to get the shape. i went to a place that made surfboard blanks, they have the foam that drips off when they are making the blanks. i got 2 kinda blocks and it can be stuch together if its not enough. you can sand it of cut it with a saw. its good stuff

How it going Bishi?

When you're cutting the foam with the electric wire, be very careful not to breath any fumes.

The fumes from polystyrene foam are *extremely* toxic.

-Dan

thanx for all the advice guys,

ive found the foam ive just gotta get off my lazy 4RSE and go and buy it lol.

Will keep posted when ive made some progress.

surfboard is definitely the stuff to use as it is fine and dense enough to get to the get the exact shape required but wont react with the resin.