Does any one know where I can buy, in Sydney, some foam blocks like the stuff used to build boards. I only need 2 small blocks about 20cm * 10 * 50. What is the best way to cut and shape the foam, what tools will I need? 
Also need a small quantity of carbon fibre cloth, where would I get that please.
I've done a search on the web, but being specialised stuff, It's come up with all sorts of other things. 
RMAX Address
27 Chifley St
Smithfield
NSW, 2164
Australia
Contact Details
Ph:1300 888 662
Other:(02) 9609 6088
Fax:(02) 9604 7747 www.rmax.com.au
give them a call and they will send you some samples of different densitity's and they will cut it too what ever size you want
and fgi for eveything elese
you will need a surf foam from the hardware
He means surform. It looks a bit like a hand plane with a cheese grater stuck to the bottom.
Clark Rubber sell sheets of styrofoam, and I am pretty sure I bought some 50mm stuff. i can't remember the sheets sizes, but they will be at least big enough for what you want.
i dont know what your doing with the foam but make sure its not packageing foam the density is very soft
Here's what I'm doing, and of course it's ultimately to do with windsurfing. Since my windsurfing wagon is not available at the moment the Subaru is the current WS vehicle.
The only problem is that it's got this big f*** off spoiler on the back which means I can barely open the boot then the gear is on top.
I've taken the top section of the spoiler off (about 2/3 rds of it), so it now it clears the gear. To cover up the holes I need to put a cap or plate on top of the horns of the remaining part of the spoiler on the boot lid.
The plan is to shape something out of surfboard foam and then cover it with carbon fibre with a polished finish. I though that would blend in with the black and the look of the car without having to do any painting. I read this article on DIY carbon overlays so I thought I'd give it a go.
Keef, it's a two piece thing, joins about 100mm above the piece on the boot. So there is a range of screw holes and openings. (I found it also had a wire tensioner running all the way around through the middle).
So now I need to seal the top sections off. ..
a pic of what it looks like.
Maybe I need to speak to Mr Love on the forum, being the design expert, he can give me some tips on the best shape for the covers.
If I get this right may even look at making some windsurf bits! 
the best way to seal it is to make something to fit over the top, useing say 8mm high density pvc flat sheet foam(thats 3 peices) and shape that,( you can use some gladwrap so that the glass doesnt stick to the job) you shouldnt need carbon just about 4 layers of 1/2" 6oz fiberglass tape on the outside, its easy to work with cos the edges dont fray ,maybe someone elese has some idea's
. Have you thought about adding to the rear spoiler and lining it up with the roof racks up front. Sure, you would never be able to open the boot but it would look 'sic' (or is that 'sik?). You could also tie your sails and boards to it.
. Have you thought about adding to the rear spoiler and lining it up with the roof racks up front. Sure, you would never be able to open the boot but it would look 'sic' (or is that 'sik?). You could also tie your sails and boards to it.
So I got my gear and I'm am now in the test production phase. Probably will end up cheaper if I buy a new spolier but not as much fun. Also a good way to kill many non windy hours.
I have struck a small problem that Chris alluded to......
I made the blanks for the piece I need out of balsa wood because in the end it was easier to get and it isn't affected by surf board resin which I believe has less tendency to yellow.
The problem is that the carbon cloth is relatively stiff so it didn't like to go around corners well and stay down, I used some tape which sort off worked. Could i put a plastic bag over it and tension down (I suppose that's what vaccum baging is all about?).
The cloth was also too stiff to form around the end bits which taper down to the size of a thumb. The carbon cloth just gathered up. I was thinking I could cut away the excess and then rejoin it, but it would probably fray when cut?.
Chris ...Keef or any other experts...suggestions.
Thanks for the tips. I'm not sure what sort of carbon cloth it is, see picture below. Also you can see the core of the shape I'm trying to cover, it's fairly fine. The carbon finish is purely for cosmetic purposes so strength is not a problem. I might try the plastic cheese wrapper and scissors, seems a straightforward option.
. Have you thought about adding to the rear spoiler and lining it up with the roof racks up front. Sure, you would never be able to open the boot but it would look 'sic' (or is that 'sik?). You could also tie your sails and boards to it.
dont take it personal des) or take them off the part and shape to whatever you like, then get some more 5min aroldite and brush on and let it cure, once cured sand and paint in the same auto spray as the car ,from auto pro,the whole job shouldn't take any more than 2 hrs a piece"painted", if i have lost you send me a pm
but were talking about isonic des imagine the tail lift you would get with 2 isonics on a wrx
I have a foam cutting factory all computer controlled in newcastle(redhead beach)
you draw the shape and i can cut it up to 2.5 m+ long use a m or h grade foam and carbon fibre it.
Redhead foamworx or foamworx.net
but were talking about isonic des imagine the tail lift you would get with 2 isonics on a wrx
Select to expand quote yes dont use gladwrap cos it is elastic and the fibers will move,and small jobs tape down with painters masking tape ,1 cose it doesnt break, and 2, resin won't stick to it so you dont need to vac bag
Keef thanks, I used a bit of painters tape last time but will need to use more. Messy process. Had resin, tape and bits of rubber glove (tape stuck well to rubber) everywhere. Second time around will be better, fingers crossed.
dez dale mentioned the cheeze wrappers what he ment was to use a plastic with the same texture,mainly cos its thin and crispy and you can stick some holes in it and it wont stretch,
dez dale mentioned the cheeze wrappers what he ment was to use a plastic with the same texture,mainly cos its thin and crispy and you can stick some holes in it and it wont stretch,
