Hello! We cut the foam to the general size needed for each area, and then on the backside, we cut a series of horizontal lines about 3/4 of the way through the foam block. This gave the foam enough flexibility to curve without breaking. We test fit it and cut a few more lines if necessary to make it more “bendy”. It takes a little patience because you can end up breaking the block but worst case you just attach that as a separate piece. If you look closely at the right-hand side of our “finished” pictures you’ll see that two of the cavities actually have 2-3 pieces in them because Andy got a little overzealous with his bending. We just put them up as separate pieces and filled in the gaps with spray foam.

Our van is a Chevy Express extended wheel base. Which is the same as a GMC savannah extended wheel base.

I’m wondering what model of van did you do ?

Hello! I apologize for the link not working, I will fix that right after responding! The reason we didn’t insulate the floor is because convection is the main source of heat loss with metal. There is a a lot of stuff under the van (axels, exhaust etc) that reduces the amount of airflow, which reduces the amount of convection heat loss. Also the under belly of the van does not receive any sunlight so it doesn’t have the solar gain that would cause heat gain in situations where you would rather be cool. It is similar to the way you don’t have to put as much insulation in the floor of your home. If your planning on using your van in extreme conditions (like regularly under 10F or over 90F you may want to consider it, but for us the cost and effort wasn’t worth the minimal benefit! I hope that helps! We would be happy to answer any other questions you may have!

Thank you,
Halan Jacobsen