Hi BW et al,
nothing happened with EtBW all summer as far as build progress goes. We did camp out of it a few times. I just started making some progress again a couple of weeks ago.
Attached 3/4" strapping horizontally to the drivers side wall. Filled in spaces with 1/2" foil faced foam board insulation. Used a coroplast (chloroplast?, chloroflouroplast? chlorofluoromonosodiumglutoplast?) product to template for wall panels, put the first 1/4" birch plywood wall panel on last weekend.
It's fun to start the project up again. Here are a couple of crappy pictures. My only camera is my blackberry.
Here is a closeup of the template material whose name shall not be spoken. I like this material a lot because: It is very flexible, it is the same thickness as my 1/4" ply material, and most of all it is somewhat transparent which makes marking very easy, easy to cut, much more friendly to use than newspaper or cardboard.
After cutting out the lower half template (sheets of this material are only 25" x 8'), I screwed it onto the plywood strapping as shown in the next pic. The strapping material in the picture is visible through the template which allows for easy marking of the screwable locations (handy later).
Next step was to install the upper template and allow them to overlap. The van top slopes downward as it goes rearward, so using a two piece template is great. A lot less tricky cutting of the template material- I just used the top factory edge of the template material against the sloping van roof and allowed the two template pieces to overlap in the middle as they please. Then I marked the window corners only with a sharpie while looking through the material. Once this was done, I laid the two sheets onto the finish plywood. The bottom sheet is flush with the bottom edge of the plywood, and the top template is registered over that one using the old window templates that I made for cutting out the windows originally.
Squiggly lines on template are a quick-and-dirty representation of the screwing locations. The strapping locations are not as regular as the studs in a modern house due to the irregular shapes of the van. Because of this, knowing where to screw through the plywood is critical not only for the sake of sheathing, but for cabinet fastening. Having these templates as a reference will be handy later.
couple pics of installed panel: