Foam replacement how to
So this isn't earth shattering information but I thought I'd post it anyway so I can feel useful.
I bought a new carpet set which clearly stated it would not come with the Mercedes backing so I knew I would have to come up with something. I poked around in the forum and came up with material ideas, easiest and best imho was straight up carpet padding. (Nobby?) What I did that is different (I think) is I started with 3/8" (1/2?) foil backed rigid foam board for the first layer. I slit the foam into two pieces where it has to bend up the firewall and rejoined it to the main piece with good quality duct tape (not that shite that rips up while you're trying to get it off the roll) all the way around the seam. I gapped the two pieces by about 1/4" to allow it to bend without interference. I thought the foil backing was a good idea to reflect the heat back at the floor instead of at my feet, only time will tell how it holds up. I then layered the carpet padding to the same approximate thickness as the original, using a medium set adhesive spray between each piece. The passenger side has a "hump" in it and the existing set allows for this hump with a rather large indentation. I just laid a piece of padding that was already cut to full shape over the hump and traced it out, cutting away the appropriate side and then using the keeper to cut 2 more pieces, adding them to my pad; thus getting the correct depth. I then used the thickest mil plastic I could get at the local hardware store (3 mil) laid the pad on it and cut the plastic to shape with enough plastic to fold over the edges and tape down with the good duct tape. I didn't want to enclose the foil with the plastic, I thought that would defeat the purpose of the foil. The whole thing was still flexible enough to get it around the gas pedal using the same slit as the original and the gas pedal appears to function freely. I haven't yet decided whether or not to glue the whole shebang to the carpet, although the original is glued. I also did the cut outs for the snaps?clips? in the corners which is also mounted to the carpet, I just haven't figured out why they are clipped together in the first place. I though at first they must somehow pop onto the floor, but there is nothing on the floor to allow for that. At any rate, the job came out rather well. Total cost for materials was about $35.00. I still have 2ft x 8ft of the foamboard and 2ft x 6ft of the padding (I purchased a precut roll rather than dick about having it cut) I'm thinking I will insulate the back wall of the trunk and possibly use some of the padding in the sidewalls of the shelf where I hope to install the speakers, making a decent barrier between the magnets and the steel of the car.