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I seal all the exposed foam areas like that with bedliner. I tested FlexSeal and while a similar product, the bedliner cures hard so is what I found to be better for the task. Just don't spray it on so thick that it the window/vent can't fit in the hole.

Getting there ! fiy, those heavy steel strips are there to reinforce for a lot of weight. Depending on what you plan to install in those locations, you can likely delete them. They aren't really structural beyond being there to support something heavy (like tool boxes, etc). Certainly won't...

Good luck on the recovery !

One thing you might look into is the spacing of the frame member studs. I don't know what the centers are on the S250 but if you can avoid having to cut into the frame members you preserve the structural integrity of the box. I downsized my fridge vent/access panel a bit so I wouldn't have to...

Looking forward to seeing the build. I've seen a couple S250's done up nicely. It's a great little platform.