I had the exact same issue "the bulge" on my '02 10-2000. I attempted drilling holes through the shell and injecting Sikaflex. It was a slight improvement, but it annoyed the hell out of me and I ended up ripping the interior out behind the affected areas. Right behind the bulge there is in fact no foam at all but rather a pathetic little piece of plywood glued to the shell in this highly stressed area. I glued (Sikaflex) a large 1" plywood reinforcement about 5 times larger than the original. By cutting the luan strategically in the interior to gain access, you couldn't tell it was ever repaired. In the end it was a lot of work but fairly inexpensive.........just some plywood and adhesive. When I had it torn apart I could see how futile injecting the adhesive from the outside was. The foam in the lower wall had come completely unglued.........the foam doesn't break apart, the glue just gives up.
