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> Rebuiding Inside-out
bbrock
post May 8 2020, 10:40 AM
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QUOTE(Kansas 914 @ May 8 2020, 08:32 AM) *

I wonder if there is a chemical that would "eat" the foam and not damage the metal?


Not fun to work with but toluene or xylene would probably do it. I'm no chemist but that stuff seems to like to eat foam in my limited experience.
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BeatNavy
post May 8 2020, 03:50 PM
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Is that the same foam used in the body above tail lights (and in sail panel)? I think @ClayPerrine recommends just spraying brake cleaner on it. He says that dissolves it pretty nicely. At least I think it was brake cleaner.
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bkrantz
post May 8 2020, 08:55 PM
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Not sure. The foam in the trunk lid rib is yellow, very rigid, and somewhat porous. What I dug out of one rear fender is white, slightly flexible, and rubbery.
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bkrantz
post May 8 2020, 08:57 PM
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In any case, I made a foam scooping and pulling tool out of a piece of 1/4 inch steel rod. Stiff enough to work but bendable to change the angle of the "head" inside the rib.


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bkrantz
post May 8 2020, 08:58 PM
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After a couple of hours:


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bkrantz
post May 8 2020, 08:58 PM
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I got 99% of the foam. And the rust looks minimal.


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gereed75
post May 9 2020, 04:45 AM
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Some brake cleaners may work to dissolve foam, but there are various formulations.

Generally acetone is effective for dissolving most plastics and foams. It is readily available at big box stores. Never really tried it on Porsche foam. Also very rough on paint. Use carefully.
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Dion
post May 9 2020, 06:24 AM
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I don’t know how I missed this thread, maybe the title threw me off.
Just read it to here. FANTASTIC WORK. I’ll be following now.
Awesome that your son is involved too. Look forward to more.
Cheers
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bkrantz
post May 9 2020, 08:11 PM
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Thanks, Dion. Doing the work, and the documentation, keeps me going.
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bkrantz
post May 9 2020, 08:12 PM
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Speaking of foam, has anyone replaced the foam in the trunk lid rib? With what?
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bkrantz
post May 9 2020, 08:13 PM
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More work on the trunk lid today. Here's the hole cleaned up.


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bkrantz
post May 9 2020, 08:14 PM
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The patch requires a double curve, one sharper and one constant radius. I got pretty close.


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bkrantz
post May 9 2020, 08:15 PM
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Fit in place.


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bkrantz
post May 9 2020, 08:16 PM
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Tack-welded in place. The thin metal around the edge of the hole behaved better than expected.


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bkrantz
post May 9 2020, 08:17 PM
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And all welded in place. Grinding tomorrow.


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bkrantz
post May 9 2020, 08:18 PM
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I also welded a small crack in the rib along the right side.


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bkrantz
post May 9 2020, 08:19 PM
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And I welded two holes in the middle of the trunk lid skin, probably from a luggage rack. I guess that was a thing at some time.


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bkrantz
post May 10 2020, 08:11 PM
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Got back to work on the trunk lid today. Grinding down the luggage rack holes I filled:


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bkrantz
post May 10 2020, 08:12 PM
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Grinding down the crack welding in the right side rib:


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bkrantz
post May 10 2020, 08:13 PM
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And grinding down the welding around the patch. I am pretty happy with this one.


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