help to cover an interior custom door.

[barned01]

if i remove any more, it won't retain any shape
it is a 3mm mdf backing (which i could cut holes in areas i don't need easily enough)
5mm mdf bottom frame.
67*42mm pine (light as) handle along the top extending the length of the door.
17*67mm (decreasing to 0mm) triangles of pine on either side of the door pocket (used to get the shape of the pocket)
3mm mdf to represent the pocket area and keep shape (probably not required)
and the speaker bit in the bottom right is made up of 2 'rings' of 17mm pine with a 12mm mdf face.
All up the whole structure wighs 1.4KGs
Where else can i remove the weight from without loosing the structure?
I also have t'shirt material instead of speaker grill material, that is alright to use as well isn't it?

[EldarO]

dude

go down to bunnings, before you do anything, and buy some MDF sealer, shits expensive, but it will prevent any swelling you can think of.

Eldar.O.

[gearb0x]

im not sure what car this is for but adding so much weight to the doors will accelerate the door hinge wear. Like most cars with long doors have (which happens to be every one ive owned, T-18, Mr2, etc)

Why not some of that cool foam stuff you can carve out to shape pretty easily, and then doo what whitzl said.

[stahlz_ae86]

im not sure what car this is for but adding so much weight to the doors will accelerate the door hinge wear. Like most cars with long doors have (which happens to be every one ive owned, T-18, Mr2, etc)

Why not some of that cool foam stuff you can carve out to shape pretty easily, and then doo what whitzl said.

Like this styrofoam I bought yestersay to do a little project I will be posting up in the tech section as soon as I start.

I bought it from a place in Somorton called "STYRAPAK AUST. PTY. LTD."

I have no idea where you would buy it from where you are but you could try calling or e-mailing them...

(03) 9308 8455
[email protected]

[stahlz_ae86]

Oh and I forgot to mention. They are really good there. The reason I initially went was to get some of the blue foam for a mate who is making a small model for one of his uni projects. I told them he was a student and asked for a few offcuts and they were more than happy to help. The above pic (those 3 blocks) cost me $10

Bargain

But if you purchase it in large blocks it's pretty cheap for what you get especially considering I think it's imported too.

When I went there 12 months back I was quoted...

$200 for a block 92mm thick 1200mm wide and 2500mm long

$103 for a block 100mm thick 600mm wide and 2500mm long

Hope this gives you a bit of an idea.

[barned01]

makew the shape out of foam, fibergalss the shape and then eat away the foam with a thinnre or something?

[stahlz_ae86]

Long story short, the way I'm going to do my project is to make a prototype with the foam, Cover a layer of PVA over the foam (or something which seals and doesn't eat) then use ordinary car bog to make the perfect shape.

Then take a Silicone mould and fiberglass into the mould.

Whether you take this route or not is entirely up to you. The foam may be cheap but silicone can be pricey.