We had anticipated using 25mm kingspan/celutex insulation and then ply floor and flooring on top. But, as we are restricted on height we changed our minds and changed to 7mm foam/silver backed insulation – the same we are using on the roof and other places and have been impressed. This gives us an extra 18mm height and every little helps!
This makes a few other challenges, and battens need to be 5mm (5mm + 2mm of bonding) to go flush with the 7mm insulation. But, 5mm wood isn’t ideal!
So, the floor has 2 front/back recesses where we were able to put 15mm thickness (x25) batten bonded in – so we’ll use these to screw in. The edges and L/R battens are only there to glue the ply to, and aren’t needed for structural support. Some support was given where there was a bit of a recess.
All minor recesses (7-10mm) were insulated with some of the foam before a final layer was filled in, then joints taped (vapour barrier) etc.
The offside step was removed and the framework built over there so the floor can be flush to the door as this is needed for the fridge.
The fuel tank sender unit has a cover behind the drivers seat which, sadly, is partly in the open and partly under the fridge. So a framework has been made there with removable panel, and this will be measured and marked. Thus if we need future access, we can remove the fridge, cut the flooring, and remove the panel easily. Much easiler than having to guess where it is and take the whole floor up (which is impossible).
The wheel arches were insulated with 7mm foam insulation and sealed with tape.
The ply lining floor needed to be modified to fit around the newly insulated wheel arches, around the step, and around the rear vent which is in the way when the floor is raised.
Getting the ply down was a right pain as it was slightly warped, so the glue and small screws into the 5mm wouldn’t hold – so good job we have loads of van batteries as we used these for weight! The glue seemed to go off overnight (phew).
The top layer of flooring is industrial grade Altro which is glued down, but currently only in the NS rear to allow us to do other things and still “roll up” the front and offside as needed.
The OS floor area is left for now pending requirements when we build the furniture