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Hmm... anyway, here is a view of the "textured" surface Tom mentioned. This piece is in excellent condition and I think the air gap is intentional, since very little if any trace of the foam remains. I'll do more research on this, but give the engineers at Ford the benefit of the doubt.
This...
Don't think so, an air space is often used for sound proofing, windows, for example and the remaining ridges are very uniform. Ford put a lot of thinking into this vehicle.
Edit: Also, the material you used, is an excellent thermal insulator, here they wanted sound proofing primarily.
The solution to sound proofing found on the m656/xm757 series, where you ride next to the engine, was a material supported by ridges to create an air space. Works pretty well actually.
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