I'm just starting to experiment with Ensolite alternatives. Unfortunately, I was not able to salvage my Ensolite. The glue that held it in place actually peeled completely off of the shell in several places, but not all. Getting the rest of the glue off was quite messy, but you'll want to leave a relatively clean surface so that whatever you stick up there actually stays put. I ended up using Peel-Away paint
remover. Pricey, but one application does the job. It MUST be rinsed out afterward because you don't want it soaking into the glass and resin. That was really easy for me, of course, because the trailer was gutted and I had the entire floor out.
Whatever you put in there, I strongly recommend some sort of insulation and reflective barrier. Those glass shells are really good at trapping heat when the sun is out. That's why Scamp
(and maybe a few others?) are using Reflectix foil-covered bubble wrap under the headliner. You may not care about staying warm if this rig will be used for vending, but not using reflective barrier under your liner may cook you along with your food.
For the headliner, I would prefer a non-textile because I want it to be easy to keep clean. I imagine that's an even bigger deal for you, maybe even a legal requirement if it's food you'll be selling. I haven't found the perfect solution yet, although I'm leaning toward some sort of coating over foam made from a special type of plastic called ionomer. This is from the same family of plastic used for golf ball skins - tough stuff. The main (only?) producer of this foam in North America is Gilman Corp. and the foam is called Softlite Foam Facts
in small quantities by McMaster-Carr http://www.mcmaster.com
, who will ship to Canada. This foam is used for arctic buoys and huge dock and boat bumpers. One huge advantage to this stuff is that adhesives, paints and coatings stick to it really, really well. I'll probably apply one layer of Reflectix and one of Softlite on top.
I'm still looking for that perfect, cleanable rubber-in-a-can to paint
it with. I tried Plasti-Dip in the spray can Plasti Dip Protective Coating Products | Synthetic Rubber Dip Coating
, but that's way too expensive and the fumes were wicked. It also left bubbles which popped and left little craters. Gallon cans are much less expensive and may give a better finish, but you'll still have those fumes. Plasti-Dip also makes some water-based commercial coatings for things like yoga mats and medical cushions, but you have to buy 5 gallons of it at a time. I'm also going to try applying glossy polyurethane caulk with a paint
roller, maybe with a bit of thinner.
For a more utilitarian coating, you might be able to spray or roll a good gloss enamel over Softlite or other foam. Whatever you use, make some test patches first to make sure it works as expected. Plasti-Dip made real Ensolite foam shrink, but was OK on Softlite. Other foams may not hold paint or glue.
I also looked at using Naugahyde, but I hate the smell of PVC. Naugahyde and a couple of other companies make polyurethane faux-leather products, but these are all cloth backed and require a bit of skill to apply. I'm lazy and would rather roll or spray something on. Still, having a fake ostrich leather interior might be kinda cool. http://www.miamicorp.com/customer/mi...%20ostrich.pdf