Battening + Insulating Our Sub Floor | Fiat Ducato | UK Self-Build Campervan Conversion

In this video we take you through a detailed look at how we installed our subfloor battening and insulation, some of the challenges we came across and how we created a vapour barrier across the entire floor.
We used 25mm x 38mm roofing battens for the frame and 25mm PIR insulation board in between. Where there were difficult gaps we used plastic bottle insulation from B&Q. I'd recommend using the 100mm foil tape as you only need one piece per batten. Also don't forget to consider how your vapour barrier will continue up the walls.
In Part 2 we will cut and install the plywood subfloor....
Times:
00:00 Introduction
01:51 Planning Your Sub Floor
06:19 Measuring and Cutting Battens
10:50 Glue the Battens Down
14:00 Cutting and Fitting the Insulation
20:44 Finishing Touches and Vapour Barrier
===========================
WHO ARE WE?
We're Mark and Neil and this is Our Van Plan. We've always wanted a camper van and took the plunge in 2020 by ordering a brand new medium wheelbase (L2H2) Fiat Ducato. We are converting it ourselves into the van of our dreams with little previous experience. We're glad to have you along for the ride!
===========================
FOLLOW US
You can follow our build in real time over on Instagram....
/ ourvanplan
===========================
#ukvanconversion #vanlife #campervan #ducatocampervan

[@NomaddUK]

I'll be doing this to my Boxer this weekend. However, I will be layin a batten then cutting a foam sheet to width then sliding the next batten up to it. Saves precision cutting the foam.

[@karenclyne4054]

I love that your cat is always around and about checking out how you're getting on and overseeing all of your great work! Watching avidly.

[@OurVanPlan]

Haha yeah she loves being out there with us. Don’t think she’ll ever be a proper campervan cat though 😂 thanks for watching 😊

[@CLdriver1960]

Well done! That’s exactly how I insulated the floor of my Promaster City (Fiat Doblo)

[@sharonlee782]

This is brilliant. I’m only in the early stages of choosing the van which I’ll be getting the long wheel base but not for a little while yet. As a woman in my 50’s I thought I’d have to get the whole build done by a professional but you are giving me confidence that I can do some of it myself. It was really great to see how easy the swivel bases were. I’m only 5 foot so will only need to add the swivel. Looking forward to seeing the rest of the build and getting plenty of ideas for my own build 😀

[@OurVanPlan]

Thanks Sharon. Great to have you along. If we can do it anyone can! It’s tough but possible. Just takes a bit longer than you think! Good luck weigh your build once you get the van.

[@christophercarr8976]

When I was cutting the insulation for my home office I used a second fix wood saw to cut it. Worked really well as it’s a fine blade but all a big blade so easier to cut straight edges, might need something smaller for the little bits though. Looking good, wish I known about the aluminium tape as I don’t have any of these on my sub floor!

[@garyposton]

I feel your pain lol. Been there. Still great to watch another van build. 👍

[@OurVanPlan]

Thanks, glad to have you along 😊

[@deranocasper]

That's a cracking job on the floor ⚒️👌 I here a electric carving knife is good for cutting insulation 💯👍

[@helloiamzoe375]

your face though when using the saw :)

[@ElliotMelloy]

In between where plywood floor boards meet it's important to get the batons in exactly the right position to support both boards. I did those batons first, starting from the front, then measured 1220mm down on the left, centre and right, and glued in the next baton, needed to do that 4 times for an L4 van, and get them perfectly square so the centre of each baton was 1220mm further back from the last. Then I moved on to the intermediate batons which can be placed less accurately, but it's best to find a good rib position (some are 2-4mm lower like you said), then cut and place a long rectangular strip of PIR, then use that to position the next intermediate baton. Then the PIR can be pulled out and labelled, later it can be cut into squares once the intermediate batons and noggins have been done. It takes more time doing the plywood edge batons first, but you also save time by using cut rectangles of PIR as guides for the intermediate batons, so it all balances out I guess.

[@richardsracingmad]

Love the cat appearance at 15mins….looked like it fell from the roof!😂

[@OurVanPlan]

Haha yeah the cat definitely enjoyed the build too 😂

[@jordansapey8707]

Hi, we have already watched all your videos but rewatching them all as we pick up our 2021 ducato Monday and you explain everything so well so thank you. Do you have a link to the mitre saw you used please as I’m looking at getting one and there are so many to choose from. Thank you 😊

[@OurVanPlan]

Hey Jordan, that’s really exciting. Bet you can’t wait. Glad you find the videos helpful. We got the Evolution R255SMS from screwfix and they also had an offer on the table which is well worth it in my opinion. Great saw.

[@westfield75]

Very professional job! Well done. It will all be worth it in the end. What was the adhesive you used please.

[@OurVanPlan]

Thank you. We used CT1 adhesive.

[@DrDSCT]

Superb videos - really enjoying watching this. Are you able to tell us where you bought the Ducato from? I was really interested in understanding more about the discounts you mentioned on the new van along with the associated discounts on the optional extras. I only ask because I’m thinking of buying a Ducato myself. Best regards.

[@OurVanPlan]

Thanks Douglas. We purchased ours from Johnson’s in Swindon. The offer at the time was a discount off vehicle price and extras which is normally quite rare. I think I used one of the pricing websites to get an idea of “best price”. Think it was autoebid.com. Having driven the Ducato a fair bit recently, it’s a great van. Lovely to drive.

[@pevans100790]

Loving your videos, very well made and clear explanations. Think i have no watched nearly all of your conversion vids. Quick question, how have you found the 25mm PIR insulation underfoot and do you feel it was worth adding the 6mm dodomatt liner also. I was thinking of going thicker with insulation but i also really don't want to loose too much height (am 6'2).

[@OurVanPlan]

Thanks for the message, glad you’re finding them helpful. The floor insulation is fine. Hard to tell if the dodo liner added much but I’d probably use it again. Floor is always warm though.

[@damienhealy823]

Hi, hoping to copy your method it's pretty good, what centres did you space all the batons & how many did you need to buy, my van is a MWB daily, thanks 😆✌🏼

[@LeeMizen]

Hi There, 👋 great build enjoyed watching very helpful 👍😊 just started my build I'm at the point of battening and insulation board, please can I ask what you did with the anchor points in the end, did you use to help hold the sub floor or did you just seal holes with the existing bolts? Many Thanks Lee.

[@OurVanPlan]

Hi Lee, so I removed them and laid the floor and then realised I didn’t do anything with them! So didn’t seal or put the bolts back which was silly. I’d definitely do that but we don’t need the anchor points inside the van.

[@LeeMizen]

@@OurVanPlan thank you for Coming back to me, I'll do that this morning then 👍

[@chriscaarnold]

Ive just bought a boxer van in H2L2. Thanks for taking the time to make these. I will be stealing ideas! Nice pussy cat🐈 !

[@cenkergin2820]

Hello, thanks a lot for very useful video. What is the thickness of rubber insulation mat you used to fill in the blanks?

[@OurVanPlan]

The black foam stuff? It’s 6mm dodomat super liner

[@cenkergin2820]

@@OurVanPlan Exactly. I guess it was enough thickness to flatten the floor, right?

[@bonkersbeast]

Hi i'm just wondering how your floor batons have held up? I've just bought a 19 plate relay and realised the floor is like yours and the ribs are unlike the older vans.

[@OurVanPlan]

Yeah all good and no problems with the floor.

[@brianscothern2569]

When you took the plastic covers off at the end of this video, did you fill the "well" with insulation and cover the plastic lid with foil ??

[@OurVanPlan]

No we didn’t put any insulation in the void as it can get water in and so we sealed and insulated over the top instead.

[@brianscothern2569]

@@OurVanPlan Thanks for info, enjoy your videos

[@Travelling_about]

Tedious job but so worth doing!

[@OurVanPlan]

It took forever! But yes the first job you don’t want to scrimp on 😂

[@thenoworriesnomad]

Good video, were those battens the blue colour when you got them??

[@OurVanPlan]

Yep, they’re treated roof battens from Wickes.

[@thenoworriesnomad]

@@OurVanPlan Thank you..

[@thenoworriesnomad]

@@OurVanPlan Hi, on your van did you have the bulkhead taken by the dealer, if so did they supply the plastic edging etc for the edges plus what model is you stereo head unit...👍👍

[@OurVanPlan]

It was a new van so factory option to remove bulkhead and therefore they supply the trim. The dealer didn’t do this. The head unit is the new touchscreen Mopar unit in 2020 vans on. Touch screen, CarPlay etc.

[@aengus.l]

Can you roughly remember how many roofing batons you used? And did you get away with just two sheets of kings pan cheers

[@OurVanPlan]

I think we just bought one pack of battens, so 8, and definitely no more than 2 sheets of kingspan for the floor. We had some battens left over too.

[@aengus.l]

@@OurVanPlan Thankyou 👍

[@sammosavi2576]

Why did you cut the insulation sheet into smaller pieces? I wanted to understand the reason.

[@OurVanPlan]

To ensure there were wood battens under the parts of the build that needs securing to the floor eg kitchen cabinets but also to brace the floor so it doesn’t flex when walked on.

[@sammosavi2576]

@@OurVanPlan thank's💚

[@brianscothern2569]

What glue did you use to Glue the battens down ???. BS.

[@OurVanPlan]

We used CT1

[@brianscothern2569]

@@OurVanPlan Thanks again