Re: cab insulation?
We got the 96+ SWIVEL Base for OEM Seat Bases from DiscountVanTruck. It's sturdy! We were trying to find a junked RV with one but came up empty. After all of the time spent we just sucked it up and ordered it. Our van is a 2001 and the swivel was an exact match. IIRC, we added our model year when ordering so they sent a true bolt on solution. Mandi removed the seat from the factory base and attached it to the new one while I was wire brushing the cab floor. Four bolts to attach the seat to the base and four attachment points to the floor.
Tricky part is the Torx bit needed to remove the seats. The two front bolts for each seat are Torx Plus T55. We were able to use a hardened T55 by going slow, making sure not to slip or bore out the bolt. We keep meaning to order a Torx Plus 55 to add to our kit.
Yup, we're going to use the existing padding as a template for making one out of EZ-Cool, attach it to the vinyl with the recommended 3M adhesive and re-install the vinyl. We may modify it for the new swivel base since it has a different foot print. We already cleaned, wire brushed and treated the rust we found on the floor with Por-15. At this point the interior of our van is almost entirely black, we've put Por-15 everywhere we were unsure of. It has that creepy "free candy" look inside.
We have added FatMat to the front doors, the absolute exterior skin, to the cab ceiling and the cargo walls. Rule of thumb we got from this forum is 35 - 40% coverage. The Ez-Cool will be adhered to the inner skin of the door and it will replace the padding that is attached to the door panels themselves. We'll be living in the van so we're hoping we won't have to revisit this, only time will tell. We've read quite a bit about insulation, keeping cool will be our priority at first, so we'll share what we do as it may be helpful. A lot of what we will do has been pieced together from here and from websites from those that have lived in these (or other) vans, BadgerTrek comes to mind.
Our tripping point right now are the cargo supports. To foam or not to foam... we have a ways to go before we get there but that will need to be solved as we add the walls.
We added our own windows, actually installed larger ones than what the van came with. That was the first thing we did. It definitely was both a confidence builder and an ego buster. We've been meaning to update our build thread. Point is, you can do this!