Diy interior side wall covers - Ford Transit USA Forum
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post #1 of 17 (permalink) Old 10-23-2014, 01:25:AM Thread Starter
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Diy interior side wall covers

Anyone have any ideas on a good poly product for making your own sidewalls? The dealer by my house has a transit I'm thinking of picking up and it just has the floor covering in the rear but I would like the walls covered on the inside also.
Thanks.
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post #2 of 17 (permalink) Old 10-23-2014, 09:18:AM
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I used 1/4" plywood on my Sprinter attached with 1/8" aluminum pop rivets. If I was to use plywood again it would be 1/8". I plan on using 6mm Macrolux polycarbonate panels on the Transit with pop rivets.
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post #3 of 17 (permalink) Old 01-21-2015, 09:08:PM
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1/4" Celtec (expanded PVC) is good but not totally scratch resistant.
1/8" thick haircell ABS which would be tougher.
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post #4 of 17 (permalink) Old 01-21-2015, 09:16:PM
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I am debating between the 6mm (1/4") marine mahogany ply and 1/4" expanded PVC. Expanded PVC will much easier to paint and install, as the ply would still need to be sealed and painted. I figure the PVC could be just spray painted in your choice of color. If you plan to cover with vinyl or equal, then expanded PVC may be over kill price wise. If this is a work van, then a corrugated plastic sheet like Ford uses is all you need.

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post #5 of 17 (permalink) Old 01-21-2015, 09:54:PM
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Originally Posted by jethaden View Post
I am debating between the 6mm (1/4") marine mahogany ply and 1/4" expanded PVC. Expanded PVC will much easier to paint and install, as the ply would still need to be sealed and painted. I figure the PVC could be just spray painted in your choice of color. If you plan to cover with vinyl or equal, then expanded PVC may be over kill price wise. If this is a work van, then a corrugated plastic sheet like Ford uses is all you need.
I used white expanded PVC for the ceiling on the Sprinter. It does not have much mechanical strength and it is easy to put marks on. It looked good and did work. I used 1/4" plywood for the wall covering. 1/4" plywood was overkill for my use. I would use 1/8" ply if I used plywood again. I plan on using Macrolux for both the ceiling and walls in the Transit. It is extruded Polycarbonate so is tough and light. I am trying to reduce the weight of this conversion by using lighter materials and less material.

2015 high roof 148" WB 3.5 Ecoboost 3.31 LS rear cargo.
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post #6 of 17 (permalink) Old 01-21-2015, 11:02:PM
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I used white expanded PVC for the ceiling on the Sprinter. It does not have much mechanical strength and it is easy to put marks on. It looked good and did work. I used 1/4" plywood for the wall covering. 1/4" plywood was overkill for my use. I would use 1/8" ply if I used plywood again. I plan on using Macrolux for both the ceiling and walls in the Transit. It is extruded Polycarbonate so is tough and light. I am trying to reduce the weight of this conversion by using lighter materials and less material.
I looked at some 3mm Okume marine mahogany (the really expensive stuff) and found that it was not dimensionally stable. While I would trust if for a lamination, I wonder if it would hold up used alone. Just not enough laminate layers to be stable. Just my thinking. With two of you commenting on softness of expanded PVC, I will have to rethink that option. Just wish I lived in a big enough area that I could locally look at and buy a polycarbonate material like Macrolux. I certainly would not afford to buy it otherwise due to shipping costs.

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post #7 of 17 (permalink) Old 01-21-2015, 11:22:PM
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With fuel for our new gasoline vans currently priced at or below $2.00 per gallon the subject doesn't come up much anymore, but Orton had calculated his Sprinter customization at adding roughly 2,000 pounds to his empty van.
Anybody have a guess as to the MPG decrease of a 1000 lb vs 2000 lb conversion to the base Transit cargo van? Saving weight where possible is great, but just curious how much it affects a rolling vs flying machine. One guy I know put in a few thousand $ in material and several hundred hours of labor in order to lighten up the interior of a seaplane by 54 pounds! He said being able to take off from smaller lakes as a result was well worth it.
We're not trying to slip the surly bonds in Transits, so is the weight reduction attempt designed to save fuel, improve handling qualities, step forward to the challenge, or just 'cause it's the right thing to do?

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post #8 of 17 (permalink) Old 01-22-2015, 07:35:AM
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Alan Mulally told the Ford engineers "if you can make it light enough to Fly, you will meet the C.A.F.E. goals made by the government.
Look @ the new Aluminum F150 (600 pounds lighter), look @ the New GT (a lot of carbon fiber in that), look at the pro. "fusion" with the carbon fiber wheels......
Look what happens when the CEO of "BOEING" starts building cars....
Right now the FORD stuff is the BEST!
Think about this........

"Its a bird? its a plane? no, it's a Transit Van!"
removing weight is anyways good, (braking is easier, etc) I will shovel the snow out of the bed of my pick up every time it snows

When BMW motorcycles went to update the design (now the GS1200) they put a pale of 60 lbs of weight in the engineering/design office for everyone to feel how much they need to get rid off till they met the goals
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post #9 of 17 (permalink) Old 01-22-2015, 10:14:AM
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Originally Posted by Longboard View Post
is the weight reduction attempt designed to save fuel, improve handling qualities, step forward to the challenge, or just 'cause it's the right thing to do?
Yes.

Interesting info: I weighed my 148" WB high roof 3.5 cargo van yesterday. It weighed 5520 lbs with full gas tank and without driver. I am curious how much less this conversion will weigh.

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post #10 of 17 (permalink) Old 01-22-2015, 01:47:PM
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Orton,


Regarding lighter weight materials, have you thought of using 10 series 8020 in some places instead of 15 series? Its half the weight its larger cousin; ~1/2 lb/ft instead of ~1 lb/ft.


I've gotten started with 8020 building custom dog crates and carts, using 10 series. I like it so far, but do wish they had a Smooth profile in that size.




And the macrolux you'll be using, is that the twin-wall 'corrugated' stuff? If so, doesn't seem like that would have enough flexibility for the curves of walls and ceiling. (but then, I haven't handled it yet, either)

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