Rear Seat Delete  Page 5


I sent those results up to the 'list and got shot down big time, so I'm back to the drawing board. 
The general consensus was that it looked too 'home depot'.  And that I hadn't put enough thought or effort into it.  There were no curves and it didn't "flow".

Basically it wasn't worthy of a Porsche and I have to agree.  So I went about following one suggestion to mold something out of closed-cell polystyrene and then coat it with fiberglass.  I came up with this technique for cutting the styrofoam(tm) with a heated coat hanger.  Basically you:
  1. First, shape the styrofoam into the general shape you want by stacking several pieces or blocks as necessary.
  2. Bend a metal coat hanger into the shape you want (profile) add duct tape for a 'handle'
  3. Heat the coat hanger with a propane torch until it's glowing
  4. Use the heated coat hanger to cut the styrofoam to shape (cuts like butta)
  5. You may have to heat it many times, it cooled for me after about 10 seconds (30-45 seconds of heating for 5-10 seconds of 'shaping'), but once I got the hang of it and could steady my hand, it was a piece of cake and way better than cutting or using a file on the styro.
Here's my 'cutting tool' for styro








Here's the passenger side fiberglassed










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