I don't know if this will work, but maybe it hsa already been tried. At Home Depot today and ran across the expandible foam. I wanted custom fit boxes for the subs in my Supra. Taped newspaper to the area where the box would be and then sprayed the foam. It formed nicely to the shape. I plan to fiberglass over the foam and then cut the foam out from the inside. Do I need to worry about getting most of the foam out or will this help it. I will try and post some pics later.
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