My big fat interior (re)build

[arctictraveller]

Damn, seeing that makes me feel all warm and fuzzy. It almost makes me want to tear out my interior and start over.

[REF]

I know, right! Super cozy....but hold that thought at least until after Baja, I can tell you from recent experience-tear down, prep and pre build stuff took a lot longer than I had anticipated! And lots of 8 hr days!

Might have to start putting in some weekend time to catch up, it’s kind of a pita, as I have a 45min+ daily drive each way to get to/from where the rig is up in Loveland. But I’ve got myself my own huge heated garage space up there across from AVC I was able to rent for the month. Good thing, it’s been chilly and rain/snow all this week.

[REF]

Moving on to getting the columns wrapped...It seems that sometimes before I can get to items on my list of things to do requires 10 steps before I can even think about getting that item done, yesterday was one of those days!
I first had to sort some electrical stuff, the Ford wiring harness, moving speaker wires, and tucking as many things in to reduce bulk.
I then stuffed the rear column cavities with insulation and covered the holes with Noico to avoid having visible sunken holes when I’m done.
Next was wrapping the columns with foam for some cushioning behind the fabric. I doubled up the foam to build up around the Ford wire harness so it wasn’t a big hump and covered the seam with foil tape to smooth it out a bit before fabric went on.
The extra fabric on the wall side will get tucked behind the fabric wrapped wall panels, the extra along the door seal gets trimmed along the pinch seam.





The last one I finished today...

[REF]

My goal for this week is to get the floor and the wall panels in, then things will be able to move forward much quicker.
We are flipping the locations of the fridge and potty to be able to fit the larger TruckFridge in and still be able to recline the drivers seat. I realized I had to do something about the fuel filler hump that stuck out quite a bit right where the new fridge was supposed to go. You can see it here if you zoom in.....

I used my multi-tool to make the cut, made a template before making the final, gave it a coat of paint, made some cuts along the top, screwed it in and sealed it with some roof sealant, gained about 2-1/2”


Covered it in Noico, and done.

[REF]

For the floor, I decided to go with Bedrug vantred version for a layer under the new ply. It comes pre-cut, it contours the floor ribs and is available for most vans. I knew I didn’t want something that would hold moisture so this fit the bill. It also adds another layer of soundproofing and heat shielding. The added bonus was that I was able to use it as a template for the ply.
I first laid some strips of Noico in the valleys for added noise reduction. You can never have enough in a diesel! You can see the cut I made to the fuel filler here too

I had to cut out the in floor storage hatch hole

Bottom with the moulded ridges

The info tag

Installed

I just had to add material to the step fill area, I used the piece I cut out from the hatch area.

Here’s the ply sitting on top of the sheet vinyl I’m using for the floor. I used 1/2” birch ply for added strength. I was able to use just 2 sheets, 3 pieces. Nice!

Trimmed the vinyl with 5” extra all around

Ply installed

Screwed and Bondo filler

[86Scotty]

You're doing some nice work Rick!

[arctictraveller]

Looking good with some serious progress.

[REF]

Thanks guys!
Another day, another project checked off.....the flooring is in! Yay
Bondo sanded down

Matt spraying in the contact adhesive

Here tis, will get a final trimming

[mgmetalworks]

That is a thorough insulation job! Nice work!

[wadewaydo]

Ooooh...


I love cool builds.


What flooring is that? Looks impenetrable.