Bodywork finished

Wow! It's been a busy few months at B-rod (finishing some really cool cars for our customers) so work on the ice cream van has slowed. 

Now that most of the spring/summer car shows are behind us, it's time to jump back on the metro van and get ready for something really exciting. 

I have been asked to participate in the HRIA Posie's Driven Dirty Tour for 2015. I was in this amazing cross country caravan in its first year and they invited me back for the tenth anniversary this year! So now I have a MAJOR deadline. The Metro Van has to be finished and ready to drive to the SEMA Show in Las Vegas by the end of October. 

So here's where we are at. The body work is DONE! Can you see how straight that side is? I'm pretty proud of the work so far and ready to sand and get it in Eurothane Primer.  

A Little Progress and a LOT of Bondo

What's worse than spreading 2 gallons of bondo?

....... SANDING 2 gallons of bondo!

But the results are worth all the effort. One side done, one more to go.

Handi Foam Insulation

Today, PJ is trying out a product called Handi-Foam to insulate the ice cream van. Here is some information from the manufacturer.

"Handi-Foam® Quick Cure Spray Foams are chemically cured systems and the cure process occurs very quickly - generally within minutes. Due to their excellent adhesion properties they provide excellent insulation by creating a continuous air barrier that completes the building envelope. This helps to improve indoor air quality, lowering heating and cooling costs and drastically reduce energy consumption."

"Handi-Foam® Sealants are designed to seal and fill small cracks, gaps and voids. Handi-Foam sealants can be applied with a straw applicator, a professional dispensing unit or a professional hose kit (for use with cylinders). Handi-Foam Sealants are available in a variety of sizes to meet many application needs, resulting in less waste on small jobs while having an economic impact on large jobs.

Handi-Foam Sealants cure when ambient moisture/humidity in the air reacts with the foam sealant creating a rigid, closed cell barrier against drafts, noise, moisture and air infiltration. Handi-Foam Sealants are tack free within 10 minutes." Contact Energy Efficient Solutions to get more information and to purchase Handi-Foam.  They will help you find the correct product and application type for your needs.

PJ has prepped the inside of the van and run all the electrical that will be in the walls that are getting insulated. In the picture below you can see his set up. The tanks and the hose are being fed inside through the vending window. There is tape and paper to protect the areas where he doesn't want foam insulation to go.

Click below to see a video of PJ talking about the set up.

Here is a still photo of PJ applying the Handi-Foam product.

Click below to see a video of PJ spraying the foam.

Here is a photo of the insulation after it was sprayed in place.

Click below to see PJ recapping the process.

Here is a picture of the finished product.

A huge thanks to Energy Efficient Solutions for helping us get the correct type of Handi Foam and allowing PJ to test out this awesome product. Check them out at http://www.energyefficientsolutions.com/Quick-Cure-Spray-Foam.asp for all your insulation needs!

Wiring the Van

PJ spent some time this week working on the electrical wiring for the Metro Van. It was important to get the wiring done now, because PJ has some exciting plans that won't allow him to do it later. More on that coming soon!

Prepping inside

PJ is preparing the inside of the Metro Van for something really special. PJ got an idea to utilize a product that isn't really made for automotive purposes on the inside of the ice cream van.

This is also a great opportunity to get up to speed with all the changes happening inside the van. Here you can see the inner wall the PJ built for structural integrity and to hold the seat belts in.

Here is an interior view of the serving window that PJ cut out of the side of the van and framed in.

And finally, here is the sealed up box that PJ built for the generator. Get a good look because the interior is about to make some drastic changes!

The cone

Want to get weird looks from your UPS or FedX delivery person? Get a 7ft ice cream cone shipped to your shop! (Want weird looks from your friends, take a photo with your new cone!)

PJ had to rig up some interior structural bracing so the ice cream cone can withstand winds up to 100 miles an hour.... From the wind.... Not at all related to driving to fast!

We are all SO excited that "the cone" is here and in its proper place on the Metro Van.

More Body Work

Now we are getting to the fun stuff. PJ is block sanding the passenger side and getting it ready for primer.

Here is the van after primer.

PJ is now fitting the 41 Chevy truck tail lights so they look like they are an original part of the van.

Check out these cool looking exhaust tips. They came from a sea ray boat!