Foam is not hard enuf to router, Try using 1/8 or 1/4 masonite or hardboard to get really sharp edges.

thanks again guys. i have a feeling that what i do for the trunk and rear shelf is going to be different from the door panels and dash. ive figured out a way to make the panels the 12 pounds total that i listed above, but with a 3/4" thick frame. since i dont expect that i will need all of that, i may be able to get them down to 10 lbs and maybe less. that still doesnt include the trunk floor or the piece that you would lean over if reaching into the trunk. both of those arent planned to have any detail and can be made much thinner.

its hard to shave a couple pounds here and there, especially when my sub has a 14lb magnet and the box will probably be another 20 lbs. but the weight savings is worth a shot for the same or a little more work.

still wondering about how the pics above got their detail????? what did they lay down and glass over? how did they do it?

I have been planning on doing all of these things to my own Chevelle for quite some time now and am at the same place trying to figure out how to do it.

My plans for the door panels were to use 1/8" abs plastic panels with high density foam for the offsets. For the trunk I had planned on using 1/4" to 1/2" MDF for the base panels and the inner long panel that will hold the sub, sub box, and amp. Then to save weight on the passenger and drivers side of the trunk use abs plastic again.

I'm just an amateur in the same position as you in regards to interior work but I have found the experts are very withholding with their responses which I completely understand.

Please take lots of pictures if possible, I'd love to see how you end up doing all of this as I'll be starting mine soon.

no problem. the trunk panels and shelf should be over the next few weeks and then im going to start on the dash. door panels will probably be last.

Sorry it took so long. It routered very crisp and easily.
http://i148.photobucket.com/albums/s...v/IMAG0033.jpg
http://i148.photobucket.com/albums/s...v/IMAG0032.jpg
http://i148.photobucket.com/albums/s...v/IMAG0031.jpg

Tracy, I am definitely not trying to go against any of your recommendations . I am always impressed by your work and willingness to help others with interior fabrication.

tony, looks good. what kind of foam and whats your source?

Just to make sure we are on the same page this is foam core. It's purpose is to be sandwiched by fiberglass.

http://www.avtcomposites.com/cgi-bin...&category=1230

Not taken bad by me so no worries, Foam that is thick is very hard to get material to lay nice with good crisp edge, Thats why just about all the pro shops that I know across the country use 1/8 and 1/4 to some degree. I only recommend what works for me, You guys might come up with something thats new and different to try. Im still always open minded about something new to use. I would like to see the results of your work also. So keep posting :thumbsup:

The foam I mentioned is meant to have fiberglass applied over it. I'm waiting for things to slow down at the shop so I can get back on my car . probably within the next couple weeks.