Finally, Spray Foam Complete!

After simply heating, for about an hour, the exterior of the metal motorhome to the proper temperature for successful spray foam adhesion, I have completed the first phase of my patented Masterbond-SP exterior wall system: application of closed cell spray foam insulation. Here are a few images of the dried foam.


That's me at the end.

Under the Big Tent

All proper castles have tents in their courtyard hiding the wonders of the world within. The bearded lady...the snake man...the world's first stucco motor castle!

I had to do a little rearranging of vehicles etc. to accommodate the final phases of my stucco motorhome. Taking down the neighbor's fence was not an option. So, the souped up van I had in a car show years ago, was loaded onto a flatbed and moved to my warehouse, my large foam truck I take to jobs is parked in the street and the motor castle is now centered in my driveway.

Once in place, the winter weather approach of spraying foam insulation had to be set up. When I do exterior spray foam insulation jobs in the winter I tarp over the entire space as I need to heat the air and the surface to a certain temperature so the foam adheres correctly. This is surprisingly much easier than you would expect. It took about an hour to get the metal exterior walls of the motorhome to the desired temperature.
Boy I would hate to be my neighbors. At least I'm adding a little color to an otherwise bleak winter landscape!
I've set up a couple of stories of staging so I can easily spray the top of the motorhome.

Final Preparations for the Spray Foam & Stucco

I can actually see the end in sight on the stucco motor castle project. This week I applied the final metal mesh finish along the bottom edge of the motorhome which will become part of the structure as I am spraying foam and applying stucco. Once the temperatures warm up a little (we've been in the teens all week) I will begin spraying foam. Here are a few pictures of this stage of the project.

I attached a hand curved metal mesh along the bottom edge. It also has foam board dams attached to it.

Above the compartment, is a 6" x 10" block which is a sample of the wall system I intend to apply. Take a look at the sample and in your mind, replace the plywood with the metal exterior of the motorhome! Also, this compartment and all other exterior components have been built out to accomodate for the thickness of the spray foam. I actually had my buddy machine me a few mounting brackets for some of the components.

Dams are applied around all windows and structural edges.

Now if only I could get the neighbors to take down the fence!

Unearthed: Early Demolition Pictures

This week I dug deep into the vaults and unearthed pictures documenting the skeletal remains of the motor castle, pre massive remodeling overhaul.

After prying off all of the old wall covering, I was surprised to see that even in the late 70's, the motorhome was insulated with....SPRAY FOAM!


The next phase was to spray the insides with foam. I covered many of the windows and removed some. (This is my son peeking through an opening in the side). Looking towards the back.

Here is the spray foam layer, looking towards the front (my son again).

The next phase was to vac-plane the foam to be flush with the metal joists and completely flat. I used my patented Masterbond SP Vac-Plane tool.

Once that was complete I was able to attach the wood paneling I am using for my wall surface.

Prepping the Exterior for Spray Foam

Now that the inside is nearly finished (final paint job, laminate flooring and carpeted ceilings is all that remains for the most part), it is time to prepare the exterior of the motor home for the application of exterior spray foam and stucco.

I'm going to use my patented Masterbond SP wall system. This system of exterior spray foam is extremely energy efficient. Basically, you are wrapping the building in foam creating a seamless barrier to moisture and the elements. Masterbond SP is super adhesive and can be applied to almost any dry sound surface - wood, metal, cement, brick etc. For more detailed information on the Masterbond SP wall system and my patents, visit my website www.sprayfoamstucco.com

Here is a video detailing the Masterbond SP Exterior Spray Foam and Stucco Wall System Process:

(Also available on YouTube.com )

I've begun the preparations on the exterior of my motor home. This includes scuffing the surface to make it rougher and easier to adhere the spray foam to. This is the same principal used when applying paint or varnish to wood; it simply makes it stick better.

I've also removed and blocked off a door and window as you can see. All remaining windows and doors will be treated with dams to hold the foam back. This is going to be a very energy efficient, warm or cool motor castle!

A Throne Room Fit for the King!

Hundreds of Cabinets Hung

What would a castle be without the occasional hanging?

My brother, my carpenter friend Tim and a few of my spray foam guys helped me sand and stain all of the cabinets. We then of course hung each of them.
I am excited for all of the storage, but am also grateful to be done with the hundreds of cabinet doors. Wow!

Here are some pictures of the finished cabinets; hung!

The luxurious kitchen. There is so much storage for a tiny space, I made sure all air space was accounted for. I even made a half drawer in front of the sink!











These are the cabinets above the sink. Deep enough to hold all sorts of pots and pans but shallow enough not to interfere with one's noggin.












This is the storage along the top perimeter of the master bedroom / TV lounge.


















This is one of the two large closets for hanging clothes.