I'm into my latest project and I've hit a stumbling point. I'm working on embossed vinyl door panels and need to make my own foam rubber shapes. I'm familiar with certain foams like the expandable type used for insulation and a rigid urethane typycally used in the marine industry. Neither of these products are right. I'm looking for a density of a seat cushion or less and preferably a two-part pourable for use in a mold.

Anyone familiar with something that might work?

Do you mean like seat foam? If you are talking about foam to give depth to your door panels, that'* the stuff I would use. Unless you are talking about something else. I think you would know about seat foam..


-justin

You have the right idea. I managed to figure out a way to pit a raised Pontiac dart logo into the vinyl but would like a piece of foam the same shape to support it.

Seat foam should be just about right. That stuff isn't very easy so carve so that'* why I was thinking of a pourable one.

Get an electric carving knife. That'* what they use on the TV shows I've seen

Good suggestion, MOS but I think the shape I need is even too intricate for one of those. Here'* what the test piece looks like:

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This was formed using the emblem off of my grille. The foam shape would need to be nearly the same. I also tried another that said "L67". If I did that one, it would be a little easier just to cut out the letters from 1/4" foam with a razor blade. I kinda like the emblem though.

gawd ur full of ideas....

How good are you with a sewing machine? You could get a square to fit the emblem, and take a sewing machine and sew around the perimiter of the emblem, then inside the emblem, then all around whatever other areas you want raised level wise. Once you are done, take a razor and cut off any areas you don't want to have foam, and sew them to the backboard.. or whatever. It'* almost 3am.. so if that doesn't make sense, the time is to blame


-justin

I'd use a harder material for the insert. You need it to support the shape. If it'* in a seat, you could use a semi-rigid material, and not feel it if it were on a softer seat. Maybe even mold it into the vinyl with heat, then carefully flip it over and fill it with silicone. Then apply it to the seat.

Well, you could always go to a junkyard and find another emblem and just leave that in there. Although that would be uncomfortable. Just an idea. But, I'm not quite sure i get what your trying to do.

Hey... silicone. I haven't thought of that. Pourable, flexible and comes in different densities. Nice.

The shapes are formed with both heat and pressure. The shape of emblem you see in the pic above is unsupported. But, if it is pressed, it becomes mushy and distorted. Inserting the emblem is also a good idea too, but these are going in the area above the armrests where the perforated vinyl panel is in the door panels. This area has a concave shape to it so the emblem would stick out too far. Here'* what the new upholstery looks like so far:

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I wanted to get perforated green vinyl and call it a day but I couldn't find any. Since it is plain, I figured I'd embelish it with the embossing. A solution may be fourthcoming though. I'm working on another "plate" that will produce recessed "L67" letters rather than raised. That way, I will just need to remove the foam backing where it makes contact with the backer board.