....IF I WAS ABOUT TO START ON THE JOURNEY THAT YOU ARE STARTING...I'D PUT THE INTERIOR IN FIRST-THEN SPRAY CLOSED CELL FOAM AND THEN ADD THE ALUMINUM AS YOU HAVE OUTLINED...2 REASONS...1.) LESS CUTTING AND FITTING[I TAKE SHORT CUTS WHEN EVER POSSIBLE-AS I'M OLD!] 2.) THE FOAM IS ABOUT 135DEGREES WHEN IT LEAVES THE GUN AND WILL CAUSE THE ALUMINUM TO EXPAND AND RIPPLE-TO AVOID THIS ADD THE ALUMINUM LAST AFTER CLEANING OFF THE STUDS AND AS YOU HAVE SAID USE SILKAFLEX OR SOMETHING CLOSE-LIKE A 3M PRODUCT...INSULATE BETWEEN THE STEEL STUD AND THE ALUMINUM WITH A TAPE MATERIAL AND FINISH WITH SS SCREWS....I HAVE USED CLEAR PACKING TAPE AS AN INSULATOR AND HAVEN'T SEEN ANY DAMAGE TO THE ALUMINUM IN 8 YEARS....ANOTHER GUY USES WIDE ELECTRICAL TAPE....WHEN SPRAYING- FILL THE CAVITY CAREFULLY AND TAKE A BODY GRINDER WITH A 9"x16 GRIT DISC TO CLEAN OFF THE STUDS AND SMOOTH THE OVERAGE...I DID SEE A GUY WITH AN ELECTRIC TURKEY KNIFE ONCE AND A GUY WITH A HOT WIRE CUTTING FOAM.....geofkaye and the Rivercity Girlz....going to Louisville for the Mid-American Truck Show this weekend!
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