Before I dropped the set screw and started this entire update process, I had picked up a set of complete insulation boards. They weren’t perfect, but I could use them as a pattern.
I used 1/8″ masonite (or hardboard) and traced out the pattern, cut everything out and then used a drill press and Forstner bit to begin drilling the holes.
I sprayed them with semigloss black paint and never got to install them. I also scored a complete set of the original insulation in great shape. The plastic protectors were dry-rotted, so I purchased clear trash bags and used the manufactured seams as much as possible. Then, I trimmed them to fit, used a lighter to melt the edges and pressed them together to form a sealed package. I even saved the original VW papers and inserted them into the insulation plastic(as seen in one of the pics.)
They turned out great. I should have taken some pics of the insulation before installing it, but I was too excited to get them installed.
The insulation boards have lasted more than five years in the garage with the Charleston humidity and still look the same as when I made them.
