Thread: Foam Filling the chassis......

Purchased on sale at 50% off. Discontinued product. Highly doubtful.

However, I like the idea of actually painting on a coating better than applying the eDead mat-type material. That was insane coverage on the car door shown in the web-site, not to mention the demonstration videos.

I could try selling the eDead, on the forum or e-Bay.

Or I could keep it and I'll do..................both!

Nope. Just kidding. I'm not doing both. However, I am considering my options.

been doing some research also to get ready for shawn's car to return turn to our shop. found this vid on youtube seems like its not that hard to do.

i think im going to do this to my mazda3 this summer.pair the foam with a few "gt spec" chassis braces and my little hatch should be rock solid.

then replace the front shocks with OEM's, keep the stock springs, get progress sways.......ride like a caddy handle like a race car

Shawn - I love the project so far... since you’re going to all the trouble to stiffen up the chassis, have you considered seam welding? It seems like you're in a good position to do it, and along with the foam, would make for a pretty stiff body.

I think I still have an old Hot Version from the late 90's on VCD where they showed the foam filling process on an R34. I'll see if I can find it. I remember they had a good demonstration of foam filling on a clear rectangular tube. The tube was very flexy and easy to twist... once it was filled, it was hard like a 2x4.

Thank you Sal. You rock.

Gentlemen, you gotta love a body-dude interested enough in my ride to do research on what I am asking them to do.

Sal, I will have both products to your shop....sh*t....tomorrow. One is already as Shepherd Square, the other is just up Hempstead Highway a bit.

Then we can experiment, and I'll buy whatever quantity we need of whichever foam.

I am wondering how to do those A-B-C-pillars and the front rails. We can look at when it gets to your shop.

And we need to fully document (pics, pics, pics) this little project. You tell me when, and I'll come over and play photographer. You could also put me to work on taping or simple prep work.


Sounds like a plan.


Gracias.

I am afraid seam welding might be cost prohibitive. I could ask Sal what the additional expense would be. Cost would be the issue on seam welding. How many man-hours is it to seam weld a chassis? My uneducated guess is, a sh*t ton.

Further, I basically have every bolt-on brace, and one welded-in (IKEA) brace. Plus the foam, which should transform my chassis to crazy-stiff (sans cage).

Not that you can ever have too rigid of a chassis.


I would absolutely love it if you can dig that up. It would make an excellent addition to this thread.

I don't have any specifics on where to seam weld an SE-R, but I do for a Miata. From what little I've been able to find on the subject (including info on an R34) it appears that the door opening (sill, A and B pillars) as well as the front and rear Strut towers are good places to reinforce. I might shy away from the strut towers myself, but the sills and pillars look like they wouldn't be that hard (especially if a re-paint is already involved).

I'll dig through my old Hot Version/Best Motoring VCD collection this weekend to see if I can find the segment. If we're lucky and I still have it, I'll work to get it up on youtube so we can include it in this thread.

Here's the graphic on the Miata seam welding spots. As the Miata is a vert, it benifits more than normal from bracing and seam welding.



Flyin' Miata : Tech: Seam welding

While you're on FlyinMiata's site, also check out their outstanding chassis brace.



It's too bad nothing like this is offered for the SE-R.

Chassis Brace update - Page 2 - SR20 Forum

^Interesting. That's my first time seeing that thread.

Damn you. ......

I have already talked to Sal about this yesterday. And I am going to do the QuietCar process. Bah, another three hundred bucks.


I am copying your build to a degree, at least on sound-deadening. Yes, I want a much, much, more NVH-free environment in the cabin. Benz-like would be superb.

Thanks for the heads-up. I'm gonna buy the 5-gallon size, and Sal is just gonna spray freakin' everything sprayable.


Awesome information. I would still have to discuss this with Sal at Alberts. I am already adding to my bill the foaming and the QuietCar.


Yup, I knew about those being offered.


Not for me, I have already e-mailed them and tried to phone them. No answer in either case. I definitely considered this for my restoration, but....

Where do I draw the financial line on a daily-driver?

Right where my wallet ends, I guess.

12/12/2009

Aha....foam sample products have arrived. Sal and I are playing Play-Doh factory with this stuff on Monday. Camera in hand.



Foam products and the recipient:


I'll keep ya'll posted. And pics should be coming fast-n-furious here over the next few weeks. The vehicle is almost done at the mechanics shop.

Let me know how the sound deadening works out for you as you will have it done and tested out long before I will.