Im not sure who originally did this (Lee?) but I tried this today... got 1" foam and cut to a rough door shape and started fitting, gutting away where it didnt pop in... but it never popped in!!!

In the end I manged to get some foam in some of the really deep pockets of the door card but couldnt make a full door card bit of foam work, hence I dont think any of the foam I put in will help at all... :-(

Has anyone ever managed this???

Jon.

 

Keep cutting and thin out the foam in places - it will go in in one piece eventually. Tight fit, but not so tight that all the poppers won't seat into their sockets. I used 1" and it goes within 3 or 4 inches of the edge of the door card all the way round.

 

Phew! Done it... lots of cutting and thinning but all done now... Cheers John.

Jon.