78 Ford 4x4 First Time Build For Pan American Trip

[jonoslade]

@BrianW yeah we did consider a body swap for a moment but decided(probably in ignorance haha) it might be more trouble than it was worth since we are planning on selling the rig down south within a year. Now that I have actually pulled the thing apart and discovered how extensive the rust is/was I think I would reconsider that choice but i'm in too deep now so it's full force ahead with what we have.

[jonoslade]

Some more body work and fiberglass, the more you sand the more you find...

[jonoslade]

The next project to tackle was the 4 inch gap between the top and body at the back of the rig. I weighed my options and stubbled upon some metal mesh lying around the job site which ended up working out perfect as the support for the fiberglass and foam that came next.

The mesh I think is actually insect screen for windows but it worked pretty well for my purposes although the fiberglass had a bit of a rough time binding to it.

Step one was to cut it to size, then I used liquid nails construction glue to secure it to the fiberglass top.

Once the liquid nails was set I use a few self taping screws to secure the mesh to the metal before fiberglassing everything together. I went a bit big on this one and tried to do one large piece of fiberglass which made it a huge pain but I was able to save it before the resin gelled.

[jonoslade]

Picture of the fiberglassed mesh.

[jonoslade]

I went back and forth a lot about how to best insulate the rig and I probably spent a bit to much time researching the different options.

Side note: Thank you to everyone on this forum for posting your experience and knowledge it has been a huge help throughout the build.

I ended up going with what I hope is the most cost effective and easiest option for my specific situation. It helped that we have a family friend that has a spray foam company and that he was already planning on doing a job nearby. That way I was able to piggyback on that and the friendship to get a really good deal. I really excited about how it turned out. I will probably have him do a touch more in certain places and we'll eventually have him paint the foam but for now I'm happy with the result.

Prepping the van for the spray foam. Similar prep to painting.

The Before:

[jonoslade]

The spray foam machine, Mike is an awesome guy and does great work. If you are in southern california and are interested in polyurethane spray form for roofing or insulation I can get you in contact. He is a class act!

Praying the interior, the plan is to mostly leave it this texture but you can sand it, shape it, paint it, or cover it with any paneling you might want.

Quick shot on the outside to finish off that pesky gap between the body and the top.

[jonoslade]

For the back, I sanded down and shaped the foam a bit to clean it up and to allow the doors to close properly. The foam we cool stuff and really pulled everything together. No more rattles and no more holes. The rig should be fully waterproof wherever it's been sprayed now.

[jonoslade]

Panoramic view with all the masking still on the floor.

[twogone]

you are ... sorry, I don't find the words...

[shadzima]

Really good idea with the spray foam.