Well, here's some useful knowledge. I used to work with 2-component urethane foam, and although it achieved 30 times it's original volume, the action was all over in less than 5 or 10 minutes. I'm here to tell you the insulating foam you can buy in a can is different stuff! I foamed the interior of my aluminum piece pictured above because the seams were starting to separate. I thought that the foam would adhere to the aluminum and hold the piece together without my having to add screws or rivets. I knew there was going to be trouble after a couple of hours because the stuff was still increasing in volume - I should have scooped it out then. By this morning - well, you can see in the right photo that it spent much of the night getting bigger and bigger. It has stopped now, but it pushed out the sides and separated a couple of the seams so the piece will never be right again.
Guess I should have done a bit of testing . . .
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