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Van 2.0: Insulation, Paneling, Upholstery

February 20, 2017 Freewheeling 2 Comments

First things first. When you start with an empty shell, the obvious first step is to insulate and soundproof it. After driving 2000 miles in an empty shell, the importance of this step cannot be understated.

Greg started off by lining all the walls and inner “pockets” with 3M insulation. He left spots for where there would be windows. He’ll fill that insulation around the windows when they go in.

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Greg then measured all of the grooves in the floor and went to work cutting 3/16″ plywood that would be polyurethaned and then glued into the grooves. This process was tedious, to say the least. He’d cut them and I’d go to work putting the polyurethane on while he moved on to other tasks.

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Once the basics were done, he started building panels for the walls and ceiling. Of note, if you’re starting from scratch: when he ordered the van with no windows, he expected it to have walls/paneling. He was unpleasantly surprised to find it as bare bones (down to the metal) as it was.

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This is not an OSHA-approved workspace

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This was also tedious, cutting each panel to size and cutting around all of the little nuances, then putting two coats of polyurethane on each.

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Once it was confirmed the panels were cut appropriately and ready to go, he started upholstering them. For the ceiling, we went with a pewter/gray tweed that is a good match to the upholstery that’s in the cab of the van, and a tonal black/gray tweed for the walls.

Between the two of us, we didn’t get pictures of the actual upholstering process because it’s pretty boring. He cut the fabric, leaving a couple of inches around the outside of the wood panels, then used a 3M spray adhesive to attach it. He folded the ends over and made cuts as necessary to create a finished look. Pretty basic stuff. He used 3/4″ self-drilling screws to attach them to the walls and ceiling (black screws for the walls, silver for the ceiling).

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Beginning with the end in mind — and because it would help while working at night — he also got the ceiling panels wired up with LED lighting.

The last picture shows us getting a bit ahead of the story because it shows the framing of some important components. That’s where we’ll pick up the build-out.

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Currently there are "2 comments" on this Article:

  1. Woods RonaldRuth says:

    Really good looking van; I can’t wait too see it !! Love , Mom & Dad (We are on Facebook,but are not sure how to use it)

  2. […] the basic steps of insulating, paneling, and upholstering the van, Greg got to work framing in the living space and garage. This was a really exciting step […]

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