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If you guys read gunluvs14's analysis for the chassis foam stiffening experiment that he did (he's the guy that did the analysis and made a huge thread on Fresh Alloy about it), he said that the reason why he went with the foam that he did was because of the weight to stiffness ratio.
He went with what he did (can't remember what he used, as I'm typing this from memory) because he said if you used the next higher up weight foam, that there was a point of diminishing results.
He also used the 2lb foam for the A-pillars I think, due to the fact that you have to spray it like upwards and stuff, and the 4lb or 8lb foam wouldn't work there.
As for the moisture issue that you guys keep bringing up, you know what? If it can get in, it can get out. The same openings that will allow for the moisture to get in, will allow for the moisture to evaporate.
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