So today became the day to Foam the Door. The 3000 pound elephant in the road was my Non G-Body G-Body Van. It needed to move ahead about four feet to give me some ladder room but, of course, that brought up another problem; four feet would slam the front bumper up tight against my welder and the 5.3 on its stand with about two feet still to go.
The solution was to carefully extract both the welder and the engine stand and move them over by the tool chest and the inner door skin on its bench. That gave me about 5 feet of floor to use. After that it was just a question of popping the van into neutral, slithering in between the rear doors of the van and the main door to the garage and becoming a human push cart to "encourage" the van to roll forward. It did and I had my room.
As I sort of suspected, the foam tubing was just sort of floating over the cleft between the door skin and the header so it was more of a decoration than an asset.
I had paid a visit to the local Bulk Hardware store and scored a 3 pack of spray bomb foam for insulating cracks and crevices and that became my remedy of choice for this exercise. Only thing is that this stuff sticks to everything including people and is hard to get off. I did not want to make this a permanent cure because I have the Door Dudes coming in early May to replace the upper door seal so the trick was to make it work but make it removable.
For the removable, what i did was to take two foot lengths of Wax Paper, cut them lengthwise to get two equal panels, fold one long edge over to to give me about an 1-1/4" of margin; made about 8 of these to use as forms.
Then, one by one, took each form/panel up the ladder with some masking tape and the foam, and, one by one, attached the forms to the upper door edge with the masking tape, using the margin I bent as a guide, then rolled the rest of the form down into the crevice between the door skin and the header to create a wax paper channel, and taped that down as well. With a form secured more or less in place, I then filled it with a pass of insulating foam in a can. Made one, pass, checked it for how well it sank into the paper channel, gave it some 'encouragement" to sink if it hadn't, added more foam to top the fill off, and sprayed it with water to encourage it to set. (Hey don't ask me, them's the destructions on the can))
Lather, Rinse, Repeat, for the subsequent 6 out of 7 panels that I had created for this and then checked it all again just to be sure and spritzed a little more water at it and back to terra firma for me.
Gave it all a few minutes to set while I figured out how to get some overspray off my left hand. (Turns out that CFC free Brake Cleaner works about the best but you do need a stiff bristle brush to go with it) and then turned the lights out to see how things had progressed.
AND I AM BACK IN BLACK!@!!!
(Caution: This type of activity requires being up on ladders, using nasty chemicals with smelly fumes, and has a fun factor of -100 on the "YEE_HAW" scale.)
So why the Wax Paper? Well, if I was to just spray in the foam it would have stuck to the header and the door just fine; the trick would have been to remove the stuff in the spring; that falls into the wire brush or wire wheel category. So, while the foam sticks to the wax paper, having the paper as a liner keeps it from sticking to the door skin or the header. Come spring, up the ladder i go, pull the tape, and out pops the foam. (At least that is the theory) See this was never meant to be permanent-permanent, only to last as long as winter and early spring. I don't plan to just yard it out and trash it, the plan for that is to remove each section on a section by section basis, number and tag it for location and store them. Should it prove that the new door gaskets and resetting the tension rail don't solve the problem, I have my foam inserts ready and waiting to use. JUst me.
Nick