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Jason_323i wrote:Also foam injection might help

I saw that in the JDM article, never used it, I can see the merits, but unsure how well it lasts, the sill has a few drain slits along the bottom edge so im not sure if its a good idea to block these up??? I live on the west coast of scotland and can get very wet.
Will look into it.

Taken from another website:
Automotive Manufacturing

Specialized polyurethane foams have been formulated to improve the stiffness and crash performance of vehicles. The foam, which is formulated to adhere to primed metal surfaces, is injected into automotive body cavities where it quickly cures to fill up to 100 percent of the cavity space. By improving the rigidity of body joints with foam, less metal is required to achieve equivalent strength. In one case, the use of polyurethane foam has enabled more than 36 pounds of net mass reduction per vehicle without lowering safety performance (Figure 3). A study of passenger vehicles has shown a 0.6 percent improvement in fuel economy for each 1 percent reduction in weight (Casadei and Broda, 2008).


I never thought about the pillar and roof cavities.

http://www.europeanplasticsnews.com/sub ... =1&id=1686

http://www.dowautomotive.com/capabiliti ... tafoam.htm