Introduction:
Installing the subfloor is one of the first and most important steps in converting a campervan. A well-installed subfloor ensures that your furniture, appliances, and other elements are securely fastened and aligned, providing a solid and durable base. In this guide, we'll explain step by step how to correctly install the subfloor of your campervan.
Materials Needed:
Thermal/acoustic insulation
Plywood of 12-15 mm thickness (recommended)
Wooden battens for the floor framework
Self-tapping screws
High-strength silicone sealant or construction adhesive
Drill
Jigsaw
Measuring tape
Spirit level
Paper or cardboard templates
Sandpaper
Step 1: Prepare the Van's Original Floor
Before starting, ensure the van's floor is clean and rust-free. If you find any rusted areas, sand them down and apply an anti-corrosion treatment. A clean and protected floor is key to a durable and solid installation.
Step 2: Identify Floor Ribs and Install Framing
Identify the ribs on the van's floor. These raised structural elements run along the length of the van and provide natural strength and rigidity. They will serve as a guide to make the framing that will hold the plywood.
Steps to Follow:
Prepare the Area: Lightly sand the paint on the ribs where you will place the wooden battens until you reach the bare metal. This improves adhesion.
Apply Adhesive: Use high-strength silicone to glue the framing directly onto the ribs. Ensure the sanded areas are well covered with silicone to prevent long-term corrosion.
Arrange the framing evenly across the van floor, ensuring gaps no larger than 300 mm (12 inches) between each piece. This will create a solid and level base for the subfloor.
Step 3: Insulate the Floor
Insulation is essential to maintain a comfortable temperature inside the campervan and to reduce noise. There are several options you can use:
PIR Panels (Polyisocyanurate): Rigid panels with excellent insulating properties and moisture resistance.
Spray Foam: Ideal for filling every corner and hard-to-reach space, offering excellent thermal insulation.
Reflective or Multilayer Insulation: Thin and lightweight materials that reflect heat, helping to maintain interior temperature.
Cork: An eco-friendly option that offers thermal and acoustic insulation.
Rock Wool or Fiberglass Wool: Effective and economical insulators, although less common on floors due to thickness and potential moisture accumulation.
PIR (Polyisocyanurate) Spray polyurethane foam
Steps for Installing Insulation:
Cut to Size: Cut the insulation material to the necessary dimensions to fill the spaces between the framing.
Installation: Place the insulation in the empty spaces, ensuring you cover every corner.
Fixation: Use construction adhesive or double-sided tape to keep the insulation in place.
Step 4: Prepare the Plywood
The plywood will serve as the base of the subfloor. Keep in mind the following:
Plywood sheets usually measure 2400 x 1200 mm (about 8 x 4 feet), so you may need more than one to cover the entire surface.
The joints between the sheets must coincide with the framing installed, ensuring a stable and firm connection.
Steps to Follow:
Create Templates: Use paper or cardboard to make templates that help you cut the plywood precisely, especially in complicated areas like wheel arches.
Cut the Plywood: Cut the sheets following the templates, ensuring they fit perfectly in the available space.
Step 5: Secure the Plywood
To secure the plywood to the van floor:
Apply Adhesive: Apply construction adhesive or silicone sealant on the framing previously installed on the ribs.
Place the Sheets: Position the plywood sheets over the framing and insulation, verifying that they are well-aligned and level.
Secure with Screws: Use reference points to identify where the framing is located under the plywood. Screw the sheets into the framing, ensuring a solid fixation. Make sure the screws are flush and do not protrude.
Step 6: Final Touches
Check that the entire subfloor is well-aligned and level. Make necessary adjustments to ensure the surface is as smooth as possible. This step is crucial for the subsequent installation of the final floor, as a well-leveled base will facilitate the placement of the final covering, such as vinyl, laminate, or another material of your choice.
Installing the subfloor is an essential step in your campervan conversion. A well-installed subfloor improves stability and comfort and ensures a durable build. By following these steps and using the appropriate materials, you'll be closer to turning your van into the campervan of your dreams.
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