The Pillar Panel.
A few posts back I mentioned the "beam" to the right of the side cargo door. I'm not sure what the correct name is but I'll call it the Side Cargo Pillar. To correctly cover this pillar requires extra work because besides the different structural elements it doesn't mate up evenly with the First Panel I installed which is on it's right. The mating problem is due to the first panel's being bowed into the van wall.


When I lined up the first panel for trimming I positioned it so there was an extra inch to the left of the left edge of the pillar.


This is so I can shift the cut panel to the right so it will overlap the first panel.


Remember this overlap when you create the template.


Cut and insulate this panel like the others.




Now to start modifying the panel. First up the Rectangular Bump.
The panel won't sit flush because of that. Need to remove some insulation to compensate.
Cover the rectangle with a piece of newspaper cut to be the same size. Roll some tape to make it sticky on each side and put on the paper. Then when you dry fit the panel push it against the paper and it will stick to where you need to remove the insulation.


Remove insulation.


Panel will fit flush now. Attach the panel with screws. Notice the gap on the bottom caused by the recess.


Want to fill the gap for two reasons. A chance to add some extra insulation but more importantly is the need to add some edge trimming. The trim will hide everything behind the panel. The fabric covering will be glued to this trim. The added insulation will provide backing to support the trim pieces.
Cut and dry fit the insulation piece. The marks are so when it comes time to glue I'll know where to position it.



You can see the gap along the right side of the pillar panel where the first panel bows into the van wall.
Into this gap, cut and dry fit foam insulation so it's flush with the panel edge.


Next step. Place posterboard in the location where you need to create a trim piece. Just run a pencil along the edge where the posterboard meets the panel.


Tape the marked posterboard to some fiberboard and cut along the line. You now have a trim piece.


Here I'm using tape to hold the cut trim pieces in place. This covers the gap seen in the above picture. The extra foam pieces previous added are behind this edging providing support.


Now to put it all together. Move all the pieces inside where it's warm enough to glue.
Use the contact cement along with clamps to glue on the foam pieces. Use the marks from before to reposition the foam pieces. I'm using a couple pieces of plywood to evenly apply pressure to the foam piece while the cement sets.


Here are the foam pieces that go along the right side of the panel


Once all the foam pieces are attached use them as backing to hold the edge pieces in place.
Use contact cement and clamps.


That's it. I won't be posting information with this much excruciating detail about the rest of the panels I build. It's just that this single panel had most all of the problems I've run into so far so it made a good example.