Step one. Bought the van.

Next up. Some more insulation.
I'd considered using something like furring strips and pink fiberglass but the Ford van's walls are too irregular and that method won't work everywhere. Next up is extruded foam insulation. I couldn't attach the foam directly to the walls so instead I'll attach it to what will be the interior panels.
Supplies:
Lowes:
Hardboard 3/16”x4'x8' - $11.21 each
Extruded Insulation 1/2” x 4' x 8' – $10.48
Woodweld Contact cement - quart - $13.98

The wall panels are a type of pressed fiberboard. They are not as strong as plywood but since I'm not using them in a structural capacity I'll save on weight. They will be covered in fabric when done.


I decide to start on the passenger side, aft of the cargo doors. One reason I'm working from here is because I'm not sure how I'll frame the window behind the driver. As I work my way around the van hopefully it will come to me.


First Mistake. Instead of a template I thought I could use a marker and reach behind the panel and draw out the where it needed cut. It worked but just barely.


Mistake Two
Double sided tape isn't strong enough to hold the foam to the panel once you start to flex it.


Mistake Three
Don't use 3/4" extruded foam with the panels. The two of them combined makes the panels so springy you'll have to use your feet to bend them into place.
(Picture taken while lying on my back trying to get the panel to curve against the wall.)


I'll attach the foam to the panels using contact cement.


Before attaching the foam remove the plastic film that covers the side you will be gluing.


Apply cement liberally.


Position foam on the board then place everything handy on top of the foam to weigh it down while the cement cures. I let it set overnight


By this time in the build I have a fair collection of foam bits left over.


Combing several of the smaller pieces to cover a larger panel is a good way to use them up.