Replacing the passenger side footwell relay cover
 

After recently bunging up my botang's, replacing my ECU box seal/cover and (hopefully) ridding myself of all other sources of water ingress, I just couldn't bring myself to refit the manky, water-damaged footwell relay cover, so I started looking at ways to replace it.

I've always felt that the choice of materials for this cover, essentially foam-backed compressed cardboard, was pretty poor, so I didn't even bother looking into replacing it with a new one. So I decided to make one ...


This was my original cover, a bit minging but in good enough shape to act as a template:

Attachment 13393Attachment 13394Attachment 13395

After hunting around for suitable material, with ideal criteria such as inexpensive, lightweight, waterproof, insulating, fire/heat resistant and easy to cut, I settled on 10mm 'tile backer board':
http://www.ebay.co.uk/itm/221471642769
Attachment 13399
This particular board was made by Nassboards:
http://www.nassboards.co.uk/Insulation-Boards-10-x-10mm

Using spray-mount adhesive, I added a thin (about 1-2mm) black foam rubber sheet to both sides then, using the original board as a template, cut it to shape using a knife. As a finishing touch, I added some 12mm wide foam rubber tape around the edge:
https://www.amazon.co.uk/gp/product/B00XH8XXBK/

This was the end result, which I'm quite pleased with ...

Attachment 13396Attachment 13397Attachment 13398

(I added the penny washers to prevent the screws from damaging the foam backing).

Nice job Mark. +++

Indeed, A job well done!

Great Job Mark! +++
Can you make up a load before the annual meet?
I'll definitely have one off you - Soul Colour Trim / Carpet please! :D

:lol:

Not bloody likely I'm afraid. It took me about 2 months to find the time to make that one!

Also, it goes behind the carpet and mats, so the colour is unimportant. The originals are all beige/cardboard colour.

I do have a large piece of Nassboard left, if anyone wants it. Free to a good home (bad homes also considered). There's probably enough to make another 2 covers at least. I've also got plenty of foam rubber tape (for around the edges) but none of the foam rubber sheet left (though that's readily available on Ebay).

Very neat. Something I'd thought of doing, but couldn't think what to use of the back. Do you still have the eBay number of the foam backing you used?

I was hoping nobody would ask that! :D

I bought it for something else, over a year ago, and I couldn't find it at the time of posting, but after a bit of digging through old emails, it seems it was Ebay item ID #111227726521:
http://www.ebay.co.uk/itm/BLACK-NEOP...-/111227726521
(3mm thick is what I used).

I was just using what I already had, although it is very similar to the original foam backing. It's available from numerous sellers it seems and it appears the same stuff is available in a self adhesive form too. Spray-mount adhesive works well though.

Someone has to ask these awkward questions Mark +++ And what do you know, they don't post to Northern Ireland.

However, as you say, there are others selling it as well, so it gives me somewhere to start looking. Thanks.

No problem. What you're looking for is neoprene sponge/foam sheet. Check that it's 'closed cell' (ie doesn't absorb water) and that it can be glued (if not buying the self-adhesive stuff).

The image in the ebay listing I posted is misleading, making it look like a rough foam. It's actually very smooth/soft to touch, with a fine/small cell structure, similar to the original foam backing.



EDIT: If you can't find a seller who delivers it to NI, let me know, I can order some for you and bring it to the meet (assuming you're going).

Cheers Mark, but had to cancel the annual meet this year. It was either that or the 'ExplorA8tion Ireland!' one.

Managed to find ones that supply to Northern Ireland, so all the bits ordered. That's yet another little job to do to the car now :D