by mike257 » Fri Mar 11, 2011 11:53 am
Doing mine next weekend - I've got a few rolls of that thermal foil stuff from B&Q, going to glue that to the roof and into all the nooks and crannies, also got some expanding foam to fill any tricky hollows I can't reach. Want to make sure all that cold metal is covered, condensation in the van has been awful when the weather is bad.
Once that's all in, I'm going to glue some battens on to the roof struts, and screw the ceiling boards into them. I'll be carpeting the boards, and also sticking some nice recessed 12v spotlights in there, so that'll all be done before it gets permanently fixed to the roof. Going to use some pretty light board for the ceiling so it can flex into shape a bit easier.
A slightly less DIY-intensive route would be to check out your local breakers yards for a minibus based on the same body as your van, and see if you can get hold of the factory headlining from that.
Good luck, let us know how you get on!