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Interior - foaming panels - Oct 31, 2009

Photo # 1 - Before spraying on the adhesive, I need to protect the area right around the holes for the each clip. If you apply adhesive all around those holes and glue the foam tightly to the backer board, it will be a real pain to try to insert the clips and maneuver them into position. To solve this problem, I apply a very small piece of masking tape to the area between the ½" hole for the clip and the original screw hole (which will be the center of attachment hole in the body). I’ll then spray adhesive right over the top of this masking tape. When things are dry, I’ll flip the panel over and be able to insert the clip by slipping it between the sticky side of the tape and the backer panel. (At least that is the plan.)

Photo # 2 - I also masked off the area where the aluminum insert will be going with my “World’s Most Beautiful Contact Paper”. I’ll be showing this later, but the insert is set into the upholstered panel by cutting away the foam in the area of the insert. Then the insert is dropped down into that pocket and attached to the backer board. If I didn’t mask off the area where the foam will be removed, I’d have to do a lot of scraping and/or sanding to get the area clean and flat. The idea here is to cut the foam around the edge of the insert and pull it out along with the contact paper, leaving a nice clean backer board. We’ll see how well this works a little later.

Photo # 3- Next I position the foam on the backer panel and clamp down one end so the foam is secure and can not move.
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