Day 26:
More progress was made today. After satisfactorily carving out the pour foam to a level I could work with, I took psychodad's advice (thanks psychodad) and went to the local Menards (our version of Lowes) and looked for some plastic/fiberglass sheet panels. I found something similar to what is in his link, but it wasn't textured and was thinner. This stuff is .06" thick, but still pretty strong but thin enough to cut with scissors.
I got out my measuring tape and pencil and marked a shape I could cut and got cutting. I went large and trimmed it to size, but I got it to fit pretty good. For the notch for the keg, I decided to go 25" high (kegs are 23 3/8" high) and 9" wide. 9" is probably overkill as I only need a little under an inch of clearance in the door, but I'd rather have too much rather than too little.
Anyway, then I got some of that spray foam because apparently I haven't learned my lesson with foam yet!
I figure the spray foam should be a little easier to control. I used it to fill in the gaps where I chiseled away too much of the spray foam, and fill in the crevices. This stuff also works like glue to keep the new inner door panel still.
I took care to make sure not to get foam in bad spots and sprayed it. That was about 5 hours ago. I just went out there to check it and take these pictures and it looks pretty nice. It feels pretty sturdy. Its a little uneven, but at this point, I dont care. Once I get the spray liner on there, it should be even less noticeable.
Last thing I did tonight was I started taping off the fridge for primering. I am going to go with rattle-can primer and then top it off with an automotive grade base coat. I know thats probably not the most ideal setup, but thats okay, I am not a professional!
So, heres what I got so far. It looks a lot nicer in person. Its nice to see it starting to come together and look like a finished unit.
