Lithuanian builds car from polyurethane foam
by Michael Harley on May 30th 2008 at 3:26PM 
Click above for an extensive photo gallery of the work in progress...
Polyurethane, the wonder-polymer used in everything from appliances and textiles to electronics and footwear, is apparently the car building material-of-choice for this "sculptor" in Lithuania. You'd recognize his particular mixture of the foam as the same type of messy stuff we use to fill cracks and gaps around windows. Tossing all OSHA and DOT regulations out the window (no problem in Lithuania), this crafty coach-builder mixes up batches of PU foam in 2-liter soda bottles before "applying" them to the framework of his creation. Held in place by scrap cardboard until it sets hard, the foam can then be sculpted, sanded, primed, and eventually painted.
Our best guess is that the rolling "donor" chassis was once part of the Mercedes-Benz family. Do yourself a favor and check out the huge photo gallery, and take particular note of the 30-inch rear wheels (not nearly as gaudy as the jacket this guy is wearing) and the upholstery treatment on the inside A-pillar. Regardless of what the designer was thinking, with that much self-expanding foam inside the cabin, airbags are most likely unnecessary. And, wind leaks are probably non-existent. Flammability, however, might be a problem. Thanks for the tip Kevin!
Gallery: Lithuanian Foam Car
[Source: English Russia]
Reader Comments (Page 1 of 3)
ckm 3:36PM (5/30/2008)
There's nothing wrong with this technique. Most concept cars have their bodies CNC milled out of blocks of foam (like this http://www.tarus.com/styling.htm), the covered in a hard substance (usually described as 'clay', but it's not) for final styling.
Molds can then be made for a fiberglass shell or you can just paint it like these guys did.
Reply
Tarakonaz 3:44PM (5/30/2008)
It's based on Mercedes-Benz CL (W215). I think it's very ugly. I am from Lithuania, BTW. He had also build similar looking car based on BMW 6 class. Here are some photos of BMW:
http://www.newsgroupu.puslapiai.lt/2007/04/03/pagaliau-baigtas-projektas-bmw-m6-645i-pimp-edition/
truckerschoice 3:42PM (5/30/2008)
Its fine for molds and such, but is highly toxic when burned. If he gets in an accident he could end up gassing the bystanders or responders with cyanide if the car catches on fire.
Reply
CarbonBlack 7:24PM (5/30/2008)
I want to go to home depot and get several hundred cans of foam-then change my civic into a ferrari
Paul 3:44PM (5/30/2008)
This vehicle is exactly what the world needs.
Reply
J3-Colt 3:44PM (5/30/2008)
Using the Borat accent "he make for Borat sexy car in which to cruise chicks for in..."
Foam for a concept car is fine, but to seriously drive this as the final product??? I'll pass...
Reply
ckm 4:01PM (5/30/2008)
Nowhere was it mentioned that this was a road going vehicle. Drivable, perhaps, but that does not mean anyone would actually do so other than to move it around a exhibit.
Whatever your thoughts are on the styling, you have to admire the skill needed to pull this off and the amount of work it took. Pretty cool.
Benfolio 3:45PM (5/30/2008)
Love (HATE) the Maximum Overdrive grille.
Reply
3seriesisking 4:41PM (5/30/2008)
It's got buck teeth out the yin-yang!!
skiwithme 3:46PM (5/30/2008)
headlights let it down badly. when you look at the frontals, cover the lights up with your fingers and its awesome.
Reply
Biomech 4:03PM (5/30/2008)
Cover up that hulk of a grill and it looks even better.
Will 3:57PM (5/30/2008)
"Words fail me."
"I'm disappointed too, but keep in mind transmogrification is a new technology."
Reply
david 4:42PM (5/30/2008)
Dont worry i got the calvin reference!
Everybody else is uneducated philistines
meshies 4:09PM (5/30/2008)
I actually like the HUGE wheels in the back.
Reply
Chase 4:11PM (5/30/2008)
this car is proof that there is no God
Reply
Allan 4:27PM (5/30/2008)
A fine example of when "because I can" just isn't enough justification.
Reply
DarkSi 4:28PM (5/30/2008)
Forget what it looks like, although I think it's ok, aside from the grill and the wheels.
That car looks FANTASTIC, considering the method in which it was made. I highly doubt that's by any means a daily driver, it's probably specifically for the show circuit... And for that, it's perfect.
With all of the time and effort this guy put in, I think it came out great. Agree with the styling choices or not, he did a great job with the symmetry, and it looks flawless.
Awesome job, Luthuanian guy.
Reply
Alex 5:31PM (5/30/2008)
agreed, its is ugly beyond compare but his technique is excellent.
PJ 6:40PM (5/30/2008)
Nevermind what it looks like...
You can bet you'd feel like a hardass if you built this out of foam, in your garage, by yourself.
Starnerf 4:44PM (5/30/2008)
Isn't the Blob supposed to be purple?
Reply