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Old 07-27-2013, 06:55 PM
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I just picked up a Dune Buggy for my wife. She wants it to take Grand kids around the northwoods. It has a little jumpseat in the back. I pulled it out, and it is moldy underneath. Pretty simple to rebuild, but wondered if there is a composite material that I can use for backerboard, rather than plywood, so we don't have the mold reoccur. Also, Dan if you are out there, what would you recommend for foam?

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Old 07-28-2013, 07:21 AM
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I would look for some 1/2" plastic like the modern cutting boards are made of. Make sure you drill a bunch of 3/4" holes in it so the foam can breathe. Here's a link: High Density Cutting Board And Bench Tops | U.S. Plastic Corp. As far as foam, I would use regular open cell polyurethane foam, and have as few seams as I could get so water doesn't get in. Don't cover the foam with plastic sheeting, all that does is create condensation, which just makes things worse. Where are you in the north woods?
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Old 07-28-2013, 07:31 AM
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Thanks Dan. Northern Michigan, near Mio.
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Old 07-28-2013, 09:39 AM
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Composites

I do a little bit of fiberglass work.

As Dan suggested, I would also use urethane foam. I get it from Aircraftspruce.com and it comes in various sizes and densities.

For the floor of my garage potato, I'm using 1/2", 2 Lb/Ft3 and covering it with 4 layers on each side and edges with 8 oz bidirectional cloth and polyester resin.

Styrofoam can be used, however not with poly ester resin- it dissolves the foam. Epoxy resin must be used on Styrofoam.

I've read where polyester resin can be used on Styrofoam if the foam is sealed with common latex interior paint, though I haven't tried that.

Since epoxy resin is spendy compared to polyester, I use urethane foam and polyester resin.

I have a tool made out of MDF for my tailgate that I plan to use to make a carbon fiber tailgate wherein I'll use West Systems epoxy resin and vacuum bag the layup. Epoxy has a longer pot life and a more predictable set up time. West Systems epoxy is clearer than some other epoxies which tend to yellow over time.

Check out aircraftspruce.com for all you fiberglass supplies. Polyester resin can be purchased at Home Despot or Lowes rather than pay to have it shipped from aircraft and have to pay a hazardous material shipping add-on fee.
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Old 07-28-2013, 10:16 AM
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Don't buy foam from an aircraft supply house unless you enjoy paying a lot more for it. Urethane foam is very expensive also, that's why polyurethane foam is used in almost everything now. Polyurethane foam is highly flammable and puts out toxic fumes when it burns. Foam used in Airplanes has to be fire retardant or fire proof and pass FAR (federal aviation regulation) codes from the FAA, which are the strictest codes there are.
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Old 07-28-2013, 10:43 AM
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Thanks for the ideas guys. These are pretty simple seats. Almost like door panels. I want to cut the backerboard to shape, lay out the foam cushion, the staple the vinyl upholstery over it, so, no seams at all. I'm planning to use a marine grade vinyl upholstery.
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