I learned the hard way. It's truly amazing how the wheel halves can cut out sections of the tube like a cookie cutter if pinched. Vans sent 2 nose tubes with my kit. I guess they figure it always takes 2. The first is a sacrificial training aid and the second is supposed to be the working tube
I worked for an hour trying to get the tube in without any pinching. Ultimately, I had to stop and sleep on it. Last night I got the tube in and wheel halves together in about 10 minutes.
Step 1: Install talced tube and inflate a bit to get all twists and wrinkles out.
Step 2: Install the wheel half with the stem hole and press it into the tire as far as possible.
Step 3: Inflate the tube a small bit to again get wrinkles out and stabilized the tube. Deflate COMPLETELY.
Step 4: Line up second wheel half and insert bolts. Start nuts on the threads.
Step 5: Press large sections of the tube out of the split with fingers. Tighten nuts bit by bit to close up while repeatedly pushing the tube out of the split.
Step 6: Once the split narrows to the point that a finger is too large to push the tube clear, I used a tool I made for this purpose. Continue tightening while checking the tube, using the tool to push it from the gap.
Here's the tool:
It's .040 aluminum shaped like a bent tongue depressor. Simply insert through the axle opening and it slips right into the gap, gently pushing the tube inside. Once the gap gets down to around .040, the tube stays where it belongs.
I did it by myself with 1 clamp. I found it easy to lay the assembly flat on my bench with just enough overhang to get a nut on 1 bolt while pressing the top wheel half down. Once the first nut is holding, the clamp is used to hold the assemble in alignment to start the nuts on the other 2 bolts.
Jekyll