Two-part polyurethane foam expanding to fill the driver’s head surround.

For proper protection in a crash, the driver’s head surround needs to be filled with foam. I placed an aluminum panel where I wanted the bottom of the foam to be, covered everything with plastic sheeting and poured two-part urethane foam into the cavity. The foam generates considerable pressure as it expands and cures, necessitating many iterations of trimming and fitting. I then sat in the car with the HANS device on, followed by many more iterations of trimming and fitting. Once the foam was cut to shape, I covered it in a single layer of fiberglass and epoxy, then painted it.