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