I remember seeing this years ago. Stumbled across it again while reading ways people make bellypans at home. Foam is a great idea for making a core to fiberglass over, and I may use the idea for bellypan, door panels, and new dash.
It's a dumb project that I'm sure some of you will get a chuckle out of: http://englishrussia.com/2008/05/29/lithuanians-and-pu-foam/
I'm actually impressed.
I'm not laughing at all....... That's brilliant!
I don't know if I'd make a whole car like that, but I can see making things like centre consoles, rear seat delete panels, etc...
This has inspired me. I was going to rob a center console out of a TC, but now, I'm going to build it from scratch. Not sure what I want it to look like just yet, but it will most definitely have cup holders.
The foam thing works. The car built on top of a random chassis, and with those huge wheels - UGLY. It's a step up from "rice" :p
I agree that it turned out well in the end. Only problem with non-urethane foam is that you need to use epoxy resin instead of polyester. I don't remember which can-foam is urethane and which is some other type. My plan for bellypan is to use pink foam from Home Depot as a base, glues together piece by piece, then apply mat and epoxy resin over the top. Tack welding some nuts to the undercarriage would give me places to bolt the bellypan up.