I used 2-inch thick Styrofoam insulation, 4' x 8' sheets, from Lowes to make my cowl. Lowes had 4-inch thick Styrofoam, but I did not need that. Blocking up the 2-foam worked ok for me. I attached the blocks together and to the engine and firewall with hot melt glue. The resin for lay up was West System epoxy. I weighed some of the foam and found it was about 5 pounds per cubic foot. I was not concerned about the printed overlay on the surface nor the foam density regarding weight. All the outside surface was sanded off during the carving stage. The 5-pound foam is easy to work and reasonably rigid for the sanding and lay-ups. After the outside lay-ups were done, the foam inside was also removed, Very little foam remained in the finished cowl.
Sid Wood Tri-gear KR-2 N6242 Mechanicsville, MD, USA ------------------------------------------------------------------------------- I am looking for any and all input I can get regarding where I can get foam. I have bought 1" and 2 " urethane foam from Wicks and paid the ridiculous shipping charges to ship a box of air. I have completed the build of my forward deck using 1" foam with good results. The downside to that effort was a complicated form with many supports to prevent the foam from bending while sanding it to shape. I have been through numerous builder sites on the KRNET looking for ideas and have tried roofing companies and lumber yards with some luck but what I found was limited to 2" thickness which has a kind of cardboard glued to both sides. I had some of this same stuff that I found while dumpster diving and was able to remove the facing but it was time and labor intensive. I really would like to use the method that Mark Langford used which will require 6" foam. Mark- any input you could give would be appreciated as well as comments from anyone else on where to get 6" foam. Where the heck does one get foam without paying an arm and leg for shipping ? I am willing to drive to pickup but am having no luck finding a source. Thanks, Jim Litchfield Va Beach VA KR2S ------------------------------
