Intro:
Ok, so we are going to install a floor in our 2021 Sprinter Van 4×4 170 (Kauila). If you are reading this there is a high probability that you have been reading many blogs on installing van floors. Good; you should be researching lots as there is a lot of opinions and justifications for choosing one type of floor over another based on what you are planning to use your van.
Goals:
Van will be used all four seasons.
Keep it simple.
Good R-value.
Floor cannot be too tall as I need the headroom.
No squeaking or movement…the ultimate test.
Strength and durability.
Moisture protection.
Sound insulation.
Floor design:
I will not list all the different websites and YouTube videos I watched as it would fill pages. I will however give a shout out to faroutride.com for the detail and research they put into their floor. Kauila will have a 5-layer floor. it will consist of a 3-layer subfloor (Minicell, XPS and Playwood) then radiant floor fabric and lastly vinyl flooring for the main living area. The garage will have a layer of fiberglass/resin then RedGard paint and finally an acrylic finish to give the garage some character.
Materials:
Minicell
XPS 150 (1.5 inch R-7.5)
1/2 Birch Plywood.
3m 90 Adhesive (Van floor –> Minicell)
Silicone II (Van floor/Minicell –> XPS) (XPS–>Plywood)
2 in blue painters tape (mask off the corrugations)
4 ft painters masking paper (floor template)
Masking tape
Biscuit Joiner for plywood.
Weather Stripping (1/4′ x 3/4″x 10ft) fits between the metal van walls and plywood floor to decrease rubbing.
Gap filler foam sealant
Steps:
Always start with good tunes!
Step 1: fill in the corrugations with Minicell insulation. Cut the Minicell into strips to fit in-between the corrugations. We laid out the Minicell like puzzle pieces and left them in in the van until all the pieces were cut and in place. Then each piece was removed in order, laid close together on the floor on top of painters paper. (you could use tape and number them we however choose to live dangerously). Before spraying 3m 90: cover the raised corrugations with 2′ blue painters tape. This really decreases the mess, gives you a clean surface to walk on and decreases clean up (3m 90 does not play well with XPS) Spray the 3M 90 freely on the van floor as well as the Minicell. Place the Minicell in the correct location while removing blue painters tape off the corrugations. Trim any excess.
Step 2: Template the floor using painters paper and masking tape. Make sure to give yourself a gap all the way around. XPS will squeak if it is rubbing against the van walls. We gave ourselves enough space to fit in 1/4 weather stripping and then some Gap filler foam.
