The ceiling material is 8mm white Macrolux. Macrolux is a twinwall polycarbonate panel that is used for greenhouse walls and roofs. Polycarbonate is a tough plastic so the panels are rigid and difficult to damage. Does show horizontal lines where the ribs are located in the material.
INSULATION BETWEEN THE ROOF RIBS ON LEVEL BACK PART OF ROOF
The inside surface of the roof was first painted with two coats of latex paint that had hollow ceramic balls mixed into paint. The balls supply some insulation. Balls bought from www.hytechsales.com. Either 1" and 1 1/2" thick polyisocyanurate rigid insulation was glued to the roof with 3M # 77 spray adhesive. The 1 1/2" was used in the deep sections of the corrugated roof and 1" in the shallow sections and at the edges of the ribs. The polyisocyanurate insulation has an R value of 6/inch. After rigid insulation was in place Great Stuff spray insulation was used to fill all the voids and help glue all the pieces together. Also notched the corners of the rigid insulation to make a hole which was filled with the Great Stuff to also help glue the pieces together. The outside edges where van sides meet the roof were filled with 1" thick Aerocel closed cell foam and glued in place with Aeroseal contact adhesive. Both supplied by www.aeroflexusa.com. Then used 3M # 77 spray adhesive to glue a layer of Reflectix insulation onto the rigid insulation. Taped the Reflectix joints with silver Reflextix tape. There is an air space between the Reflectix and the 8mm Macrolux twin wall polycarbonate ceiling. Because the white Macrolux is still translucent, there is a 1/4" layer of white Thinsulate glued to the top of the Macrolux to make it opaque.
INSULATION FOR SLOPED SECTION BETWEEN THE CAB AND THE FLAT ROOF
Painted steel with two coats of paint with the hollow ceramic balls mixed into the paint. Since the rigid polyiso would not fit tight against the curved steel van roof, 1" flexible Aerocel closed cell foam was used to cover the area. The Aeroflex flexible insulation has an R value of 4.1/inch. An additional 1/2" of Aerocel was added on top of the 1" in the center of the section. Used Aeroseal contact adhesive to glue foam to steel and foam to foam. The foam was not covered with Reflectix. The level Macrolux ceiling starts about 14" back from the rib above the back of the drivers seat on the high roof Transit. There is a sloped section of the Macrolux between the rib above the cab seats to the level Macrolux. Added a 3/16 x 1 1/2" angle across the van with 1/4-20NC tapped holes to give a method of bolting the sloped Macrolux polycarbonate ceiling material in place. Found two existing holes in the Transit body work on both sides to be used to bolt angle to the van. The angle is mounted about 5" back from the cab headliner.
LEVEL MIDDLE SECTION CEILING
The 8 mm white Macrolux ceiling material is level. It is not bent to match the van roof curvature. There is a spacer between the level Macrolux ceiling and the van rib on the van centerline . The center section of the ceiling is bolted to the ribs. Made a 2 1/4" thick spacer at each rib on van centerline. Bolted a 1/4" thick 1" wide aluminum plate to the rib with a tapped 5/16-18NC hole on van centerline. The plate plus two nylon 1" diameter 1/2" thick nylon spacers make up the spacer. The outside edges of the Macrolux sit on top of the 80/20 cabinet framework. The Macrolux ceiling is 1 1/2" wider than the space between the 80/20 horizontal extrusions. Ceiling is installed by sliding panel panel over one extrusion 1 1/2" and then back 3/4" so Macrolux overlaps on top of the extrusions 3/4" on each side.
There are Macrolux side ceilings between the rear overhead cabinets and the front sloped Macrolux. The side ceilings are lower and flush with the bottom of the extrusions and are level over to the sides of the van. So side ceilings are level but about 1 3/16" lower than the center portion of the ceiling. A wood ledger is provided on each plywood wall cover to support the outside edge of the side ceilings. The side ceilings are bolted to tapped angles on the 80/20 horizontal extrusions next to the center portion of the ceiling.
The Macrolux ceiling has 1/4" thick white Thinsulate glued to the hidden side. A bit more insulation and the white color makes the somewhat translucent Macrolux a solid white color.
REAR STORAGE CABINET CEILINGS
The polyiso rigid insulation is covered with indoor/outdoor carpet inside the rear above bed platform side cabinets. Did fill the void between the rigid polyiso and the van side with closed cell foam before the carpet was glued to the polyiso.
REAR WIRING BOX
Installed a 80/20 extrusion across the back of the van just above the top of the rear doors. Bolts to the end of the upper cabinets. Made it a box by adding a plywood bottom and front to create a box for wiring. Discarded the stock Ford wireways that are above the rear doors. Installed one of the stock Ford LED lights in the bottom of the box with a on/off switch next to the light.
ABOVE THE CAB INSULATION
1/2" Aerocel, 1" Aerocel and 1/4" closed cell foam was used over the cab.. First a 1/2" layer of Aerocel was glued to the steel in the deeper center and the two roof sides. A 1/4" layer of closed cell foam was used between the 1/2" Aerocel to level the surface. Then a 1" layer of Aerocell was glued to the first layer. Did not remove the Transit ceiling panel. Just installed the foam as close to the windshield as far as I could reach.