Quick background...I joined this forum a couple weeks ago and have been poking around and searching since trying to research a project I want to do with my driver's door panel on my '97 Nissan Maxima. Basically, the top half of the armrest rubs against my leg to the point I need to do something about it so can fit comfortably in the car (I'm 6'5"). After I buy a spare door panel to mod, I want to remove the top half of the armrest (there's a factory indentation dividing the armrest along its length) and build a fiberglass replacement section set in about 1/4" to 3/8" smaller than the stock design and with a larger radius edge to make it more comfortable. Closed cell foam (is there a better choice?) will build up the smaller armrest so that it's roughly the same size or slightly smaller than it is currently and add more cushioning. Then, I'll take some of my leather I have (been working on other projects for the car with it...check homepage) and sew a new cover, hopefully with a french seam to class it up a bit. All the door panels will have leather inserts where it's currently cloth so I'm thinking the new armrest will look pretty snazzy. My question, seeing as this car is a daily driver, what kind of adhesive can I use to A) attach the closed cell foam to the new form and B) attach the new leather cover to the foam? I'll need something capable of holding up to freezing cold, super hot (black interior) and direct sun so I won't have to redo my work in a few months. Anyone have a specific product they can recomment?

I haven't worked with leather, so I will pass on your b) question.
I've used 3M can spray adhesive products with great success on attaching foam to plastics and metals. For ex., I glued a big piece of foam to the bottom of my Japanese car's plastic radiator and it is still there (it does get hot there). Pentaflex spray can (not sure about the spelling) that PepBoys sells is a P.O.S. product, again in my opinion.

Of course, the great way to find out is to try it yourself on a sample. You can always return the can back to the store.

Regards,
Denis

I tried the spray can adhesives with little luck. The first time I put a headliner in a car I stopped at my friends shop; he specializes in auto upholstery. He gave me 2 yards of material and some green adhesive. The glue worked so well I have been using it on everything applicable. It comes in blue or green. I don't know what it's called, try an auto stitch shop to see if you can buy some. Or, if there is a swimming pool repair/supply store near, ask them what they use to attach the foam to a pool before installing the liner. That stuff is an aerosol can and I have had half decent results when in a pinch!

Yeah, try an automotive upholstery shop, they can sell you the same industrial stuff in a can that you wont find at Lowes or a Hardware Store. Some good brands are, Wildwood, DAP, Columbia Conbond, 3M. 3M Foamfast is a good spray glue sometimes found at Lowes or the like.

Thanks a bunch people...though I don't exactly own a classic car, I do appreciate the craftsmanship that people put into their hotrods and this board is full of knowledge. I'll try to post pics of my progress once I find a cheap donor panel.

I am an upholstery shop......glue the closed foam down with Landau/ vinyl top adhesieve,,,,Sounds like thats what that upholstery shop gave you.....It comes in red and green so you can see your coverage when you spray it..........Why couldn't just cut the height down of your arm rest and reinstall the orginal pad?? Or cut down the pad ??? Mr. Upholster......check out my site...***