The ceiling material is 8mm white Macrolux purchased from Tap Plastics. The Macrolux is a twinwall polycarbonate that is used in the construction of greenhouses. Polycarbonate is a tough plastic that is rigid and difficult to mar. The Macrolux does show horizontal lines where the ribs are located in the material. Easy to cut with a jig saw. Does have some insulation properties due to the air pockets between the ribs. The flat back middle section of the ceiling is made with two Macrolux panels with a seam just behind the back of the slider door. Indoor/outdoor carpet was used for the ceiling inside the two upper rear cabinets. The ceiling is level with a spacer between the van rib at the center of the van and the ceiling edges sit on the cabinet top 80/20 extrusion. A sloped transition from ceiling height down to the cab headliner was required in the high roof Transit. The side ceilings above the refrigerator/shower cabinet and above the slider door are level but lower than the center section.
INSULATION BETWEEN THE ROOF RIBS AT LEVEL BACK PART OF THE ROOF
The inside surface of the roof was first painted with two coats of latex paint that had hollow ceramic balls mixed in the paint. Ceramic balls bought from www.hytechsales.com. Either 1" or 1 1/2" polyisocyanurate rigid insulation was glued to the roof with 3M77 spray adhesive. The 1 1/2" was used in the deep sections of the corrugated roof and 1" was used on the shallow sections and at the edges of the ribs. The polyisocyanurate has "R" rating of 6/inch. After rigid insulation was in place Great Stuff spray insulation was used to fill all the voids and glue all the pieces together. The corners of the insulation were cut off so there was a hole between the pieces that could be filled with Great Stuff. The outside edges where the van sides meet the roof were filled with 1" thick Aerocel closed cell foam and glued in place with Aeroflex contact adhesive. Both supplied by www.aeroflexusa.com. 3M77 spray adhesive was then used to glue a layer of Reflectix insulation onto the rigid insulation. Taped the joints with Reflectix silver tape. There is an air gap between the Reflectix and the polycarbonate ceiling. Because the white Macrolux is still translucent, a layer of 1/2" Thinsulate was glued to the top of the Macrolux to make it opaque.
INSULATION FOR THE SLOPED SECTION OF THE ROOF BETWEEN THE CAB AND FLAT ROOF
Painted the steel with two coats of the insulation paint. Since the rigid insulation could not fit tight against the curved van steel, 1" flexible Aerocel closed cell foam was used to cover the area. The Aeroocel flexible foam has an "R" value of 4.1/inch. An additional 1/2" layer of Aerocel closed cell foam was added to the center section. Used Aeroflex contact adhesive to glue the foam to the steel and the foam to foam. The foam was not covered with Reflectix. The level part of the ceiling starts about 14" back of the driver seat on the high roof Transit. There is a sloped section of Macrolux from the flat back down to the edge of the cab headliner. Added a 3/16" x 1 1/2" aluminum angle across the van with tapped 1/4-20NC holes to provide a method of bolting the sloped Macrolux ceiling material in place. Found existing holes in the Transit bodywork on both sides that were used to bolt the angle to the van. The angle is about 5" back from the cab headliner.
LEVEL MIDDLE SECTION CEILING
The 8mm white Macrolux ceiling material is level. It is not bent to match the curvature of the roof rib. There is a 2 1/4" spacer between the level Macrolux and the van rib on the van centerline. A 1/4" aluminum plate and two 1" thick nylon spacers make up the spacer. The outside edges of the Macrolux sit on top of the cabinet upper 80/20 extrusions. The Macrolux ceilings are removable. Above the refrigerator/shower cabinet and above the slider door the ceiling is 1 3/16" lower than the middle ceiling. A wood ledger is used to support the Macrolux at van wall side of the ceiling and tapped aluminum angles provides a tapped hole on the edge next to the ceiling center section to bolt the ceiling in place.
REAR STORAGE CABINET CEILINGS
The rigid ceiling insulation above the rear storage cabinets is covered with indoor/outdoor carpet. The void between the rigid insulation and the van walls was filled with 1" closed cell foam before the carpet was glued to the insulation.
REAR WIRING BOX
Installed a 80/20 extrusion across the van between the two upper cabinets level with the top of the rear door frame. Made it a box by adding a 1/4" plywood front and bottom. Discarded the Ford plastic wireway and ran the Ford loom and my cords in the box. Installed one of the stock Ford LED lights and a on/off switch on the bottom of the box.
ABOVE THE CAB INSULATION
Used 1/2" Aerocel, 1" Aerocel and 1/4" closed cell foam above the headliner. First a 1/2" layer of Aerocel was glued to the van steel on the deeper center and on the two roof sides. The 1/4" closed cell foam was used to level the surface. Then a 1" layer of Aerocel closed cell foam was glued to the first layer. Did not remove the headliner. Just installed the foam as close to the windshield as I could reach.