George, I read your build as you suggested and took notes and found it to be invaluable.
The cat condo was not done to the same level of care that I would use for a camper. The weather was really cold here when I started, 10-15 degrees at night and I was trying to speed the process for the sake of these three litter mates who are about 5 months old and making it on their own without mom. So I did not fair the seams, nor did I continue to roll the canvas with the dry roller until the canvas was nearly dry. I rolled until it was nice and flat and seemed to be well embedded in the glue and adhered. I did get a few bubbles during the prolonged cure as I'm working in a 60-65 degree space not during summer heat. I also did not sand the foam or clean with alcohol, I already felt guilty about the time it was taking to get this outside for these kittens. As it is, it's water proof and plenty strong enough and should provide adequate insulation (plus the heating pad )
KC, I'm not sure how to characterize the level of effort to remove the canvas but I expected something like separating industrial level velcro. It was more like removing packing tape.
There was some foam particles on the back of the canvas but not a layer of foam where the foam failed before the glue. That made me wonder if it was the temperature at which I applied the glue and canvas (60-65) or a lack of preparation of the surface. The glue had been applied 4-5 days prior to cutting out the door and testing the canvas adhesion and it felt dry. I have already made the floor for the slide in truck camper while I was waiting for parts of the cat condo to dry. One side of the 2" foam is glued with TBII to 1/4 Luan and the other side to 3/8 fir plywood. Both layers seem to be well stuck and very flat. I just want to be certain about the canvas before I start the lower section of the walls of the camper. In terms of timing I'm estimating that gripper was applied 2 days post glue-up. 24 hours later, first coat of Glidden top coat. 2 days later the door was cut out and I separated the canvas from the foam.
I'm wondering if the glue had not fully dried and the layers of Gripper and top paint maybe delayed further drying?
Thanks for the help and advice, Tim