Continuing with the insulation of our van, which apparently has turned into a multi-part series, we are finishing the floor.  You may recall from a previous post the details of how we were insulating the floor, and may also recall that we only installed two of the three sections of foam/plywood.  The main reason we didn’t complete the floor all at once is because we ran out of foam.  The foam we’re using only comes in 9 foot by 4 foot sections.  It’s really a pain since we only needed a 2 foot by 5 foot piece.  Maybe we’ll find something to do with the extra foam later, but for now, it seems like a big waste.  Anyway, it’s now finished.

Floor not finished

Since I forgot to include a picture of the actual end result of the floor last time, here is what we started with today.  You can see in the picture that we kept the factory sliding door plastic step cover.

Kept sliding door plastic step

We want to keep the plastic step cover in the rear as well.  This is how it looked before.

Floor not finished

Even though we only have a small section left to complete, there are more curves and corners than straight edges, making for a tedious task.  First, the plastic trim was removed.

Rear plastic trim removed

With the cargo mat pulled back, you can see where the floor ribs have a gap in them, following the snake-like curve.  The floor piece will basically follow that.

Rubber mat pulled back

We made a detailed cardboard template, then cut it out of the foam and plywood.  Not wanting to also buy a whole sheet of plywood, we used scraps.  However, this meant that we’d have 4 floor sections, instead of just 3.  The foam was spray-glued to the plywood, then the plywood got two coats of varnish to help protect against moisture.

Rear floor pieces

Once dry, the pieces were fit into place with a little persuasion.  The entire floor was not covered because we wanted to keep the plastic trim piece and didn’t want to change how it mounts.

Rear floor pieces in place

We elected to skip bolting these pieces to the floor because we don’t want the metal floor to look like swiss cheese, and it’s not likely that anything will be anchored to these wood pieces.

The lighting in the next picture makes it look like the floor is wavy with the cargo mat down, but it isn’t.  The mat is just creased from being folded over.

Rubber mat replaced

Finally, the black plastic trim piece was replaced.  The cargo mat just barely tucks under it.

Kept rear door plastic trim