9. Raised Floor Installation & Fabrication
When originally planning my van build I had not put much thought into the flooring. I knew what look I was going to go for, and assumed it would be a pretty straight forward install, no different than putting interlocking flooring in a home. To make the concept even easier, my van came with floor decking already in place in the rear of the van. After evaluating the setup in person and comparing it to my overall design however, I realized it was a bit more complicated.
Seating Height - My front seats swivel 180 degrees toward the rear of the van. This will allow me to incorporate the front for purposes such as dining and make the front much more useful overall. What is often overlooked is that the floor of the cab is sloped upward toward the front of the vehicle. The seats are set to a height appropriate to this slope. When rotated 180 degrees to face the rear of the van, the floor at your feet when seated is much lower and makes the seating feel awkward. Raising the floor of the van levels it to a more natural and comfortable height for the front seats when rotated for use as part of the living quarters.
Floor Insulation - Raising the floor separates it from the metal body of the van reducing the ability to transfer temperature and noise. The space left behind between the van body and the new raised floor offers a great place to put insulation to for even better sound proofing and thermoregulation. This additional space can also be a good opportunity for routing some wiring, or can even be used for storage in unique circumstances.
Planning the Raised Floor
Before you start drilling and cutting, it’s essential to plan your raised floor project carefully. Consider factors such as space utilization, weight distribution, and the materials you'll use. Proper planning ensures that you get the most out of your raised floor without compromising safety or functionality. Keep in mind supports along base of the future galley, supports for the rear wheel well boxouts, if you will have a shower pan where will it be, and even where you might install anchors or L Tracks. Careful planning of the floors framing can offer structural support for some of these features.
Sketch out a floor plan that includes the locations of these items, placement of storage compartments, or any other features you want. Planning is the key to a successful van conversion project. For my build, I took a Black marker and transferred my design sketch to the floor physically. From here I could take accurate measurements and ensure the plan would work. A well-thought-out design will make the van build much more enjoyable.
Choosing the Right Materials
Selecting the right materials can impact the quality and durability of the raised floor. I am prioritizing, lightweight yet durable materials throughout my van build. For the raised floor, I am framing the structure with 2x2 lumber, and using Plywood as my base subfloor. For insulation, I am using rigid foam board insulation. The subfloor will be covered with Vinyl interlocking flooring tiles. My flooring will be trimmed out with aluminum trim or L-Tracks where appropriate. All of these materials are durable, and moisture-resistant to prevent damage from spills or condensation.
Installation of the Raised Floor
Essential Tools for the Job
Having the right tools on hand is essential for a smooth installation process. Basic tools include a marker, tape measure, T-square, circular saw, jig saw, power drill, screws. Depending on your design, you may also need tools for cutting and shaping insulation material. A sharp knife will work fine for the rigid foam board.
Preparing the Van Interior
Begin by clearing out your van's interior and ensuring the floor is clean and dry. Remove any existing flooring or obstacles that might interfere with the installation. My van had a flooring deck made of two large pieces of plywood. I removed these to prepare for my new floor but found them to be handy templates for creating my new subfloor. This is also a good time to check for any rust or damage that might need attention before proceeding.
Cutting and Assembling the Floor
Using the floor plan design and measurements created earlier, build the 2x2 raised floor framing. The ribs of the vans flooring are offset, so I started with the frame members that run across them. Once all the framing was; measured, cut, and laid out, I predrilled and secured it all together with framing screws. For a secure fit that wont shift during travel, adhere the frame to the floor of the van with an adhesive such as liquid nails.
Measure the spaces between the frames for insulation and cut the foam board accordingly. Place insulation tightly into all the open cavities.
Covering the new floor with plywood subfloor can take a bit of thinking. The unique shape of the floor can be tricky to map out, and requires multiple pieces to be created for it to be covered effectively. I used the original decking that came with my van as a guide to map out the shapes onto the new plywood and cut them out with a jigsaw. Secure the new subfloor panels to the raised floor frame using screws, ensuring a snug fit. Check for any sharp edges or uneven surfaces and sand them down for a smooth finish.
With the subfloor installed and secure, we can install whatever flooring finish we desire. My vinyl flooring tiles interlock with a tongue and groove design making the install very simple and relatively quick. Start from the drivers side front, and work your way toward the passenger side. This allows you to use the sliding side door and rear doors for access.
To finish it out nicely and hold the terminating ends in place, I trimmed the flooring edges with angled aluminum sticks. I added an L-Track to the rear door edge of the flooring, as well as the divider between the rear garage space and the rest of the cabin. These modular L-Tracks will be used to help secure gear throughout the adventure van in the future!
Final Thoughts
Installing a raised floor in your conversion van is a transformation that enhances your entire van life experience. By optimizing space, improving comfort, and increasing your insulation value, a raised floor makes life on the road more enjoyable and efficient.
