S4 DHC Rear cockpit panel.

[Bruce Crowthorne]

I just used the "Millboard" for the curved panel, but for speakers I mounted a thin aluminium "firewall" vertically between the strut towers. This now forms a front "wall" for the boot, might help a little if there was a fire in the boot (not much with ten gallons of petrol in there!) and it is a good place to mount speakers.
To ease the muffling I drilled a bunch of holes in the Millboard at the speakers and then just glued the carpet over that.
Bruce

[GrUmPyBoDgEr]

I called into the company that supplied the plastic sheet that I used on my restoration.
They gave me some samples, see Photo & I now know that the material is a hard foam made of PVC.
It's bendy & springy, technical jargon that
The stuff's called FOREX classic (registered trademark) here but it should be fairly widely available.
The thicknesses shown in the Photo are (rounded up) :-
1; 2; 3; 4; 5; 10 & 18,6 mm
I've got no facts on the actual density; best I can say is "it's light"

The texture & structure of the material may be visible in the picture on the thicker samples.
It's a shame that there's no "feelavision" but I would consider the 2mm or possibly 3mm sheet to be the most suitable for purpose.
The thickness could be doubled up locally for loudspeaker mounting etc.

Cheers
John

[fatboyoz]

Thanks Everyone,
Went to a plastics shop as per Dave and John, and ended up using 2mm clear polycarbonate. This is the same material used in modern headlight covers and is very strong. It is easily trimmed, with a Stanley knife or metal shears, and readily bends to the required shape. The shop cut it to the correct shape using the old panel as a template and also cut out all of the holes for a very reasonable price. Think they were quite happy to get rid of an off-cut. Now to carpet it and that will just about finish the interior.
Regards,
Colin.

[GrUmPyBoDgEr]

Great,
job done then
Cheers
John