Due to the time crunch I was unable to construct decent exhaust ducts for the hot and cold air. We spent Saturday digging out foam and constructing quality exhaust ducts. Things were going well until we tried to re-spray foam into the sections we had cut out. We used a common crack sealing foam thinking it was similar to the DOW Froth-pak. We assumed wrong. From the pictures you can see how well the foam turned out. We decided to continue on with the project and fix our foam problem later.
The next step was to construct our interior housing. We cut the side panels first and also cut the duct cut-outs for the interior fans. Then we bent the remaining section of the box. The last step was to paint the acrylic. We chose to paint it in order to hide the yellow interior foam color. We finished the day after we painted the acrylic sections.
Foam job #2: Filling the sections we cut out
The results of our second foam job
Cutting the interior ducts
End sections painted
Prepping the acrylic for bending
Painting the interior box
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