Van Floor System: drop in van conversion kit with insulation and radiant underfloor heating

Our floor system now seems so simple. But it has taken years to perfect.

When we first began designing our floor system we had several goals. We knew the floor system had to include an effective layer of insulation, beyond R5 with no thermal bridging. The floor must be mould and mildew resistant and as waterproof as possible. There had to be wiring loops integrated to reduce the complexity of wire runs through the van. We knew we wanted to integrate an inflow gradient heating loop to ensure the van could handle the colder winter temperatures here in Canada. All of this had to be made in an adaptable modular system that worked with any layout. And our biggest goal of all; the whole system had to be easy enough to install that anyone could do it.

The insulation layer of our floor kit complete with wire runs for radiant underfloor heating.

Many of these goals were achieved by selecting the correct materials. We sourced highly compression resistant foam for the insulation layer, achieving an R value of 7.5. This is not your usual home insulation material and is specially made for our application. This material is fully waterproof, and so prevents any mold and mildew. And, by bonding this layer in we eliminate any thermal bridging too.

The insulation layer of our drop in, van conversion floor system.

The top floor is made from 12mm baltic birch. While this material is not waterproof, it has a high level of damp resistance and won’t mold or warp if moisture does get to it. Ultimately this top floor will be covered by a waterproof finish floor (for example a luxury vinyl or a laminate) which ensures any spills that do occur do not affect this layer of the floor. Baltic birch also has excellent hold when screwed into, allowing accessories to be secured without the need to fully drill through the van and bolt underneath, (although we do still recommend this for heavier items that are not secured to the walls).

A challenge of this floor system was the development of the cut out geometry. On the bottom side of the foam layer we have matched the cut-outs perfectly to the ribs of the Transit floor and created openings for spare tire accesses. Any imperfections in Ford’s manufacturing process have been accommodated, and we’ve ensured the floor can be dropped in and fit perfectly first try, without any need for modifications.

The cut outs, designed to line up perfectly with the ribs of the Ford Transit floor.

Our latest version of the floor even includes markings that indicate where it is safe to drill through both the floor and the van, so no ribs or supports are in the way below. The benefit of these small additions are the countless hours they save. We know from our own experience the hours on end that go into measuring and recutting during a DIY build. But this system removes the guesswork and allows such a quick and easy install.

Markings make it easier to know where to cut in the latest version of our floor kit.

If you’re interested in installing this floor system into your own van, we have several options available. You can select your floor system with the radiant heating loop built in here. Or select the version without underfloor heating here. Both are completely insulated and cut to perfectly match the Ford Transit van’s floor ribs and contours. And both include the powder coated trim and printed spare tire access trim.

Something else we’re extremely excited about bringing out is our Foundation Kit. This kit (which includes the instant drop in floor we’ve been talking about today) contains everything you need to begin your van life journey. We’re talking floor, walls, ceiling and our entire RANGE bed system. But also all the behind the scenes components you need when first starting out your build, such as insulation and sound deadening. It really is the easiest way to start your van conversion off right, and the simplest way to have everything you need to start life on the road, in an easy to install package. We’ll be bringing out more on our Foundation kit soon, but if it’s something that interests you send us a message today. We’d love to walk you through the system and show you what we’ve been working on.

The finished floor, topped vinyl plank flooring, with powder coated trim.