Leaderboard

I have added interior panels over the ugly window cutouts. 3mm Alupanel was used and the cavity behind the panel is stuffed with 12 oz. of Polyfil for sound deadening and insulation. The plastic layer in the sheeting also serves as a barrier. The process was somewhat involved and required several steps. Heavy paper patterns were developed first. Next the patterns were transferred to cardboard. Cardboard was cut out and holes were punched, the targets being the three 3/8" threaded holes in the frame. After some further adjustments and a test attach of the template using the actual bolts, the carboard pattern was used to mark out the shape on the Alupanel material. The shape was cut out and the edges filed and sanded smooth. Getting the panels attached to the van walls requires some force. The material must be forced inwards to allow the 1 1/4" bolts to get started in the threaded holes in the walls. This is due to the slight curvature of the van's side walls. Large rubber washers cushion the panels on both the front and back. Before snugging down all bolts 12 oz. of Polyfil were stuffed between the panel and the wall. A long stick was used to push the Polyfil and adjust it into place. A test fit of the panels without the Polyfil revealed that the material does actually deaden sound.