Panel installation continued.
The first panel was to reach from the floor to the metal edge below the penthouse top. This measured out at 50 inches. Since the uncut fiberboard is 4' x 8' I cut the 50" lengthwise so the panel is 48" wide.
After this first panel I changed my mind about the length for the following panels. Instead of the floor I'll have the next panels stop at the metal lip that runs around the van about a inch from the floor.
Position the panel far enough to the left so it covers the "beam" that is to the right of the passenger side cargo door. Cut to fit.
The piece of panel that is removed from over the beam will be used later. I'll come back to it.
The insulated panel will be pushed up tight against the van wall. At this place in the van that's a inward bowing of 3 inches.
(The tape measure is upside down.)
I didn't insulate the top three inches of the panel to help reduce the bow by a 1/2 inch.
Along the van wall is a ridge the runs horizontally near the center line of the panel. I attached the panel to this. I predrilled then used #8 sheet metal screws. I'm using sheet metal screws in three lengths. 1", 1-1/4" and 1-1/2". I don't want to take a chance of putting a screw through the outer van wall so I'm using the shortest size that will hold. I'm probably being over-cautious.
At the moment I'm holding the panel in place with three screws. I'll probably add more later. Draw a line across the panel so You'll know where to position the screws.
With the first panel installed create a template for the next panel.
The template is 49" long but for economy's sake I'll use the 48" of the fiberboard and make up the final inch with just the foam. When I glued the foam to the fiberboard leave extra on the bottom then use the template to trim.
Install second panel.
Here is the bottom of the panel with the foam showing. Once it's covered with fabric it should look OK. You can see how it's resting on the ridge that runs around the van just off the floor.
One more thing. I forgot to not cover the top few inches of the second panel with insulation so it'll match the first panel. I found out what a good job the contact cement does while removing the already glued insulation.