Chassis Siffening Foam

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Chassis Siffening Foam

Postby NixVegaGT » Wed Jan 24, 2007 10:24 pm

I thought this was worth a thread: Originally posted by Jim (myvega) and Roy (Fastmax32168).

Subject is stiffening the chassis by filling unibody support voids with structual expanding polystyrene. NOT to be confused with GreatStuff or other hardware expanding polystyrene products that don't have a curing agent.

Here's a link to the manufacturer:

http://www.foamseal.org/auto_aftermarket.htm

Here's an article talking about it's use:

http://www.stormowners.com/GSOPDatacent ... iew/id/110

Pretty cool idea. I am planning on doing this and I'll post the results...
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Foam Filler

Postby dragmonza » Sun Mar 18, 2007 3:53 pm

Just something to consider. I would be concerned about trapped moisture when doing this. If I were to do this I would make absolutely sure of sealing the area to which the foam has been applied. Even though this is a structural foam, it can still absorb & hold moisture. Properly sealed afterwards this appears to be an easy method of stiffening the chassis.
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Postby NixVegaGT » Sun Mar 18, 2007 5:26 pm

Thanks for the input, Phill. They say that the foam finishes as a closed-cell water tight construct but it's better to be safe than sorry, so point well taken. Being from the top of the rust belt I'm pretty concerned about rust so I've taken extra efforts to close off the voids so far. I haven't foamed it yet because I'm still preparing/sealing the frame rails. I figure I'll drill holes and apply the foam and then weld the holes closed... I'll post my results.

Thanks again, Phill.
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Postby Sirshredalot » Mon Mar 26, 2007 11:39 pm

Hmm...I wonder how much it would take to do both rocker panels.
I have easy access to mine seeing as how they both have holes rusted in them right where they meet the kick panels.

I wonder how much of a difference it would make.

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Postby NixVegaGT » Tue Mar 27, 2007 8:25 am

They claim somewhere around 60% stiffer frame members that have the foam installed. I think it will take about six cans... I might buy a case since I have two projects currently...
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Postby Sirshredalot » Tue Mar 27, 2007 12:49 pm

But look at the price....for the price of a case you could buy a couple sets of alston subframe connectors.
Or a couple 6pt cages.

Thats stuff seems pricey once you would start buying enough to do one whole car.....Welding is cheaper....and stronger.

But Id still be interested in using it if it where half price or given to me or somthing.

God bless
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Postby NixVegaGT » Thu Mar 29, 2007 11:31 pm

I'm doing a bit of welding as well. The benefit is in the foam is weight savings. Helpful in racing applications. I can do 2 cars for a case. Spread over two projects it comes out to $185 per car. My frame rails cost about $35. LOL! But they did add 40 lbs. This foam will add 5-6lbs total...
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Postby marco_1978_spyder » Sat Jul 07, 2007 9:01 pm

The lower frame rails act as drains too. So if you seal them up water that enters from the cowl
will only have a small slot behind the front wheel.

You could seal the whole thing up. The car would seem super rigid and quiet then. But no airflow vents.
That might not matter in a race only car though I imagine..
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Postby NixVegaGT » Sun Jul 08, 2007 11:03 am

So the vent spaces don't just drain out the slot at the bottom of the fender? It looks like that is the only place on my Vega that drains this void... Is it different on the Monzas?

Thanks, Marco. It's good to be cautious.
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Postby shoebox1.1 » Mon Sep 24, 2007 7:09 pm

so if i fill my rockers with the foam the hood drains will go out the front fenders too?
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Postby NixVegaGT » Tue Sep 25, 2007 9:13 am

I'm feeling pretty confident that the vents don't drain into the rockers on a Vega. The only way to be sure though would be to pop off the vent in the kick panel and use a mirror to look down...
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Re: Chassis Siffening Foam

Postby VEGA327 » Thu Oct 02, 2008 10:50 pm

Vega rockers are open to the cowls and air/water from the cowl definately travel through them.
You would need to weld or seal the inlet at the cowl and the outlets for air and water to prevent water getting trapped in the foam.
Also, you would have to alter the cowl drain area so it all flows out the bottom of the cowl panel. It does this already from the factory, but it would have to be reshaped to make it all go out the cowl instead of both rocker and cowl.
The only way I know of to access this area with room to see what you are doing is cut an access hole in the side of the cowl.
I only know this because I had rust repair to do there and had to open up the cowls anyway. I found a bunch of dirt and pine needles clogging most of the drain areas.
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Re: Chassis Siffening Foam

Postby NixVegaGT » Sun Oct 05, 2008 1:23 pm

Good point. I never got around to using the foam. I will say that after I welded in the frame rails I fabricated it made the chassis REALLY stiff. Just the other day I was reassembling the suspension (FINALLY!!!!) and I jacked up the front corner just a touch. Like about 1/8" and I heard a clunk from the rear of the car. Since it's up on stands right now I was pretty freaked out. I got up and went to see what happened at the rear of the car and found the rear jack stand on the same side was also off the jack stand but 1/8"! COOOL! I still think this foam process could do a lot but the drainage could present a problem.
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Re: Chassis Siffening Foam

Postby gerbsinmd » Sun Oct 05, 2008 6:59 pm

could you get around the drainage issue by inserting a small piece of PVC pipe in the rocker before you fill it with foam and just let it run thru? Or does it drain out at a couple points along the way?
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Re: Chassis Siffening Foam

Postby NixVegaGT » Thu Oct 09, 2008 10:43 am

I'm pretty sure, on the rocker it's just a drain at the back of the rocker am. Right in front of the rear tire.
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