Our new Gem Green Moto Van has arrived! - Page 11 - Ford Transit USA Forum
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post #101 of 108 (permalink) Old 10-21-2016, 09:47:PM Thread Starter
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Originally Posted by LDH® View Post
How about some more gratuitous bike shots

Was hauling vintage Norton's yesterday among others


Sweeeeet !!!

2016 T250 148" MR Cargo 3.2L 3.73 LS all around windows
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post #102 of 108 (permalink) Old 10-21-2016, 10:17:PM Thread Starter
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Some follow and progress report is in order. I've been busy but not posting enough.

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I got a quote today to a do a white vinyl wrap for the flat area of the roof, about $425. It looks like 5 years about what I could expect from it before it gets too bad to be able to peal it back and replace it again.
I had the white vinyl wrap done on the roof. Taking readings it lowers the temp on the surface of the metal about 20 deg F on average, well worth it.





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post #103 of 108 (permalink) Old 10-21-2016, 10:24:PM Thread Starter
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I decided to use quite a bit of Noico sound deadening material against the metal prior to adding insulation. In the upper "nooks and crannies" I fed in reflectix instead for heat control. This included the area over the cab and all the upper edges.

Here's some shots of the Noico in the lower areas and on the roof.





In the sliding door
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post #104 of 108 (permalink) Old 10-21-2016, 10:35:PM Thread Starter
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After the Noico material went in it was time for insulation.

I decided to use recycled denim batting in the walls and a sandwich of (2) 1/2" thick foil faced EPS boards with 2 layers of bubble wrap in the middle for the roof.

I used the 5" thick batting in the walls.






After the batting went in I sealed it with thick polypro sheet similar to what the factory does.


Here's some photos of the EPS sandwich board




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post #105 of 108 (permalink) Old 10-21-2016, 10:41:PM Thread Starter
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Then I started making the cover panels from expanded PVC sheet. This particular brand is Komatex but it's the same as the others. I used 6mm thick for the roof and sidewalls. I did the roof in light grey and the sidewalls in black. I will use 3mm for the upper sidewalls above the windows but I haven't finished those yet.

I made CNC cut router templates for making the cutouts in the panels.







I did the ceiling in sections instead of trying to do a large sheet. This was more manageable and also makes it easier if I want to remove only a section.




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post #106 of 108 (permalink) Old 10-24-2016, 11:45:AM
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Really nice pictorial sir!
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post #107 of 108 (permalink) Old 10-24-2016, 09:07:PM
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Yep, and great workmanship!
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post #108 of 108 (permalink) Old 10-25-2016, 02:22:AM Thread Starter
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Thanks guys.

The next up is making the split folding bed platform. The sheet you see in the last photo is the 1/2" thick honeycomb aluminum I'll used for the platform.

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