VAN FLOORING PERFECTION (Insulation, Subfloor, Covering, L-Track & Step/Lip Trim)

We installed high-end DIY flooring in our camper van conversion with L-Track and this video will show you step-by-step how we did it.
Sailrite Fabric: www.sailrite.com/Chilewich-Ik...
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Timestamps
00:00 Introduction
00:31 Making a Floor Template
01:53 What is R-Sheathing?
02:28 Cutting the Flooring to Fit the Template
03:37 Flattening the Floor With Insulation Strips
06:06 Opting out of in-floor heating
06:56 Cutting Grooves for L-Track
07:43 Rough Cut Floor Covering
08:09 Secure the Floor in Place
08:32 Gluing the Floor Covering to the R-Sheathing
09:35 Bolting L-Track to the Floor
11:04 Installing Rear Step Trim
14:01 Building & Trimming the Side Step
18:15 Installing Front Lip Trim
19:25 Trim Spare Tire Lowering Mechanism
20:23 Final Results

[@martinbecklen6486]

Would have been nice to have you explain how you determined where to install the L-tracks. Otherwise, a great video. Thanks.

[@scopex2749]

To make a template I always use old newspapers. They are easy to fold into all the shapes, tape the pieces together then lay them on a big sheet of card. Ive used this on numerous camper conversions and trailer and RV rugs.😊

[@EXPLORISTlife]

Nice!

[@mlake07]

Damn...you guys have a supernatural level of patience. Good work.

[@studiolivingroom]

Love the quality finish of your work. Definitely more time is spent with some pretty tedious steps, but the end result looks professional, durable, and beautiful.. Well worth the extra effort. Great job, guys!

[@EXPLORISTlife]

Thank you very much!

[@trishtimmons4336]

I love this! I have been going back and forth with various ideas of how I want to do my floor, and this would be very suitable for my needs. Thank you so much for sharing all your knowledge and expertise!

[@sassybackpacker1526]

Thanks for this video! I have been trying to figure out how to avoid letting water get under the floor and love how you handled that in the front, and on the sides with the floor protruding a little over the steps. This is fantastic to understand the process of making a high end floor!

[@krzysztofkoscielski409]

Dang, I think it's the best flooring I have ever seen, superb job!

[@EXPLORISTlife]

Thanks so much!

[@DaytonaShooter]

Wow... Such detail and precision. Your explaination of intentions and technique are so thorough that they transcend your specific application. You've opened my mind to a whole new level of possibility and approach. Even though your tasks are very specific to your wants, the sharing of the indepth process makes it applicable to other people's wishes. Amazing teachers and designers. Thank you for showing me the way. There is, 'good enough' and there is, 'as good as it can be.' this video is a clear demonstration of the latter.👏

[@EXPLORISTlife]

Hey, Maurice, I appreciate that. Thanks for watching! 🙂😀

[@BigRedVan]

I swear everything you guys is do is professional as hell, like attaching the L-Track was one of most beautiful parts of this video lol

[@scottmitseff4402]

Totally awesome craftsman’s installation! Very impressive. Thank you for the excellent narration of the project to.

[@EXPLORISTlife]

Hey Scott Mitseff, Thanks so much! Cheers!

[@drewwilson8756]

Very impressed with the subtractive design work on the aluminum guard when you introduced an angle in as well as the scuffed finish.

[@EXPLORISTlife]

Thanks! All 6 of my brain cells were firing that day.

[@terryridge4596]

LOVE the cardboard approach! Detail is mui importante indeed and cardboard is cheap and easy to find and it's what I use on almost EVERY project! Aloha ~ ~ ~

[@clintstinytrailerconversio5560]

Spectacular work and choice of material. Best floor I have seen. Thanks

[@EXPLORISTlife]

Hey Clint's Tiny Trailer Conversions, Thanks so much! Cheers!

[@redbeard1233]

Glad to find you guys wife and I plan on building out our sprinter as a mobile bike shop and eventually turn it into a camper the l track idea will allow for modifications easily

[@troydehn2149]

“Gave osha the finger” made me spit out my food

[@EXPLORISTlife]

😂😂😂

[@csn10]

@@EXPLORISTlife That, the Cardboard Aided Design program, and the polyiso R-value coefficient divided by the hypotenuse... :)

[@GirdHerd]

Very nice, Nate. I'm thoroughly enjoying the build.

[@EXPLORISTlife]

Glad to hear it!

[@aleksilepisto7282]

Another option for templates if you don’t want to use cardboard is buying patterning paper. We use it in flooring to make templates for cutting in vinyl or marmoleum or safety floor. Your method also works though :) also rolling the carpet prior to installing the tracks would make it faster. And you can sometimes use a shop broom, flipped upside down so bristles stick up and slide the wood or plastic bottom along the floor to use it as a roller. Looks great!

[@paulikjahgirian6090]

I’m looking my converting , then I watch your work seems like you are from another planet , now you make me embrace to show my van to my friends ( complete perfection)

[@EXPLORISTlife]

Hey, Paulik Jahgirian! I appreciate that. Thanks for watching! 🙂😀

[@garryc8744]

Fantastic to see a true craftsman in action!

[@EXPLORISTlife]

Hey garry c, Thanks so much! Cheers!

[@owenparker6651]

I've been wondering how I was going to cover that back end of my floor and was thinking aluminum angle but I was stumped on how I could bend it to match that curve. So thanks for the great idea as I like your solution. I'll look for some c channel, but knowing the angle can do an ok job is reassuring and loving that method of making that bend...

[@ArshadKhan-mx2qw]

Nice video with the right speed to make people understand in the first attempt itself. Post videos in parts for complete van build.

[@rickm1380]

That looks awesome Nate!! You guys did a great job!

[@EXPLORISTlife]

Hey, Rick M! I appreciate that. Thanks for watching! 🙂😀

[@danialaho5543]

👍 Thanks for the detailed tutorial. Your concise talk-thru helped for me to tackle my project with a foresight of the completed job. Kudos to you 😊

[@EXPLORISTlife]

Glad it was helpful. Cheers!

[@jackmason7518]

Good Morning. I just love the work you two are doing. Keep up the Great Work. Jack

[@EXPLORISTlife]

Thank you! Will do!

[@mfgxl]

Glad to see someone going to more of an extreme than myself to do it right. Congratulations on you project.

[@EXPLORISTlife]

Thanks! 🙂🙌

[@madforit9661]

I think you have done a great job guys, nice and tidy finish. Look forward to the next vid

[@EXPLORISTlife]

Hey spooner Fpv, Thanks so much! Cheers!

[@richardmarquardt6246]

Great job - looks great and very functional.

[@EXPLORISTlife]

Thank you! Cheers!

[@TheNobodyZone]

I really appreciate your attention to detail. Very nice job.

[@EXPLORISTlife]

Thank you very much!

[@bsuecm]

Love the blade in the table saw hack. Sped up my cargo trailer conversion significantly, used to do with a track saw.

[@EXPLORISTlife]

🤣😂 I've used it SEVERAL times since then too. Also works REALLY good on those 3/4" thick rubber horse stall mats with a couple of passes.

[@masaki_kusa]

GREAT attention to details! Awesome job!

[@EXPLORISTlife]

Thank you very much!

[@darrylpeterson7500]

Your DIY track saw is fantastic. Definitely going to steal that idea 👍

[@EXPLORISTlife]

It works wildly good. Using MDF or particle board is key there as it stays straighter and is more flat than real wood.

[@nbkfj5r]

Great choice in materials and well executed!!!!

[@EXPLORISTlife]

Glad you like it!

[@matthewyoung2076]

This have been a fun video to watch, great job and hope to see more from you down the road.

[@EXPLORISTlife]

Hey Matthew Young, Thanks so much! Cheers!

[@TommyBackwater41]

It is very satisfying watching someone do something well . Good stuff .

[@EXPLORISTlife]

Thanks! 🙂🙌

[@CraigG21]

Impressive work! 👌

[@64maxpower]

I love the cover you used for the spare tire access

[@EXPLORISTlife]

Thanks! Yeah, I think that turned out great as well!

[@rhendersbee685]

Excellent attention to detail. For the side step support, an alternative to your boxing in between the steps is to link the top and bottom steps with a threaded rod. We found the lower step as well as the upper had too much give underfoot, but the threaded rod stabilized both.

[@EXPLORISTlife]

Probably so! Thanks for watching.

[@brucemontgomery8136]

ty in the process of watching the build i like your content and presentation

[@MrMaikeul]

This is absolutely brilliant. Awesome video production as well. Definitely getting inspired for modifications to the rear compartment of my 4Runner. :)

[@EXPLORISTlife]

Hey, Operation Wetmushroom! I appreciate that. Thanks for watching! 🙂😀

[@hassanshah1829]

Your ingenuity and hard work is amazing! The floor looks beautiful and extremely well made. This is an epic series and love every episode of it. I can’t wait for the remaining episodes (as I learn something new with each new video) :) All the best with the remaining part of this build!!!

[@EXPLORISTlife]

Awesome! Thanks for tuning in!

[@davidmcmahan7534]

Looks AMAZING, WOW!!

[@EXPLORISTlife]

Thanks so much!

[@jalilmendoza]

Nicely done! Thank you for sharing your wisdom!

[@EXPLORISTlife]

Glad it was helpful!

[@waynec2962]

Another great video as always! Thank you!

[@EXPLORISTlife]

Hey Wayne C, No problem! Thanks for watching!

[@jimhanty8149]

Damn guys, that is a totally well done project ..im impressed with how much attention is paid to look and be done right…

[@EXPLORISTlife]

Thanks! 🙂🙌

[@tumbleweed1976]

Thank you both! Well done.

[@EXPLORISTlife]

Thanks! 🙂🙌

[@simba9225]

master craftsmanship great job

[@EXPLORISTlife]

Hey simba, Thanks so much! Cheers!

[@zakmohammed5156]

One of the best flooring ever

[@EXPLORISTlife]

Hey Zak, Mohammed, Thanks so much! Cheers!

[@oneworld2642]

Love your works man ... Awesome, patient, relentless. Lexus quality.

[@EXPLORISTlife]

Hey, One World! I appreciate that. Thanks for watching! 🙂😀

[@lessard2020]

Thanks for this instructive video, learned a lot of neat tricks, Cheers from Canada!

[@EXPLORISTlife]

Hey, Benoit Lessard! Thanks for watching! 🙂😀

[@rudivandoornegat2371]

Wow! That's a really great job you guys have done. And I like the videography too: not too fast or too slow; just right

[@EXPLORISTlife]

Hey, Rudi van Doornegat! I appreciate that. Thanks for watching! 🙂😀

[@JBLewis]

Bonus points for the deck cover for the spare tire mechanism!

[@EXPLORISTlife]

Thanks! We are super happy with how that turned out too.

[@kyllikki9]

WOW… Simply incredible! 😮❤😮

[@EXPLORISTlife]

Hey K Robertiello, Thanks so much! Cheers!

[@Alto832]

Great job Steph

[@EXPLORISTlife]

Thank you!!

[@helmiyoussef3741]

The only thing i get from learning english is i can watch and learn from this kind of videos thank you

[@alexcheney6692]

Nice work!

[@fester.]

brilliant as always

[@EXPLORISTlife]

Glad you enjoyed it

[@timc7787]

Your videos are sooo good! They are giving me confidence to do a build myself. Loved the comment in one video where you put a blanket down as to not scratch you workbench with the solar panel!!😂😂. I saw several people ask about the source of the L tracks: I didn’t see a response: also, do you know if they are DOT approved for seats? Thanks for everything!!!

[@Epifani_Days]

Amazing work 😊👌

[@EXPLORISTlife]

Hey, Tore Andre Ekerhovd! I appreciate that. Thanks for watching! 🙂😀

[@afsharisohrab]

Hi.! --Great and beautiful work.

[@MattBoltonMusic]

This was your best video ever in my opinion. Really well done. Perfectly filmed and explained. Keep up the great work.

[@EXPLORISTlife]

Hey, Matt Bolton Music! I appreciate that. Thanks for watching! 🙂😀

[@tedpreston4155]

Watching you install the L-track had me comparing the relative strength of the similar structure I just removed from an old Chevy conversion van. They built a structure to strengthen the floor so that it could safely attach the seats and belts. The thing was just massive! It was steel, and it probably weighs 100 pounds, including the OSB they used to fill in the spaces between steel rails. It was almost two inches thick. I'm going to enjoy the added headroom now that it's gone! I almost never have passengers in the van, so the only seat that will be attached to the floor is the rear sofa' bed from the conversion van. without passengers sitting there, it doesn't need that massive steel structure to hold it in place. I'm planning to bolt it down again using the same bolt holes in the floor, and recycle the bolts. On the subject of recycling, I'll also recycle the washers that they used under the van, to reinforce the strength of the sheet metal floor around the bolts. The washers are massive, heavy steel and huge!

[@EXPLORISTlife]

🙌🙂👍

[@NSWMods]

Thank You Steph & Nate Agree Look Great. Did i miss the solar Build ? See u Next week Take Care Guy's

[@daviscrt]

Looks bad ass. Thanks Don

[@edhill8986]

I just bought a 2000 search and rescue box truck from my local fire dept. Has 13. 641 original miles. It has all the bells and whistles that I need and this video just saved me a lot of money thank you thank you thank you

[@EXPLORISTlife]

Very nice!

[@CLdriver1960]

Good job on the L Track installation. I had hard points on the floor of my Promaster City to work with. My floor covering was a vinyl interlocking, floating floor. As for the aluminum moulding, I attached it with construction adhesive. The floor itself is 3/4” Extruded polystyrene, supported by 1x3 battens, and covered by 3/4” plywood. I wanted to maintain a 1000lb cargo capacity which is why I laid down the 1x3 battens. The floor looks good, stays reasonably comfortable, even in below freezing temperatures.

[@Anand1111988]

Looking to do my flooring using the battens approach as well. May I ask how did you secure battens to the floor? - bolted down or glued?

[@CLdriver1960]

@@Anand1111988I used construction adhesive to secure the battens. I didn’t apply the adhesive along the whole length of the battens, only in spots along them. This allowed the adhesive to secure the battens and allowed easy removal if need be. Hope this helps.

[@ZillaYT]

CAD - Cardboard aided design, 😂. I became an instant fan.

[@mattgirgenti3595]

wow! The floor came out GREAT! nice work. As I watch, I am always thinking which items are one-off custom for that build versus what will be used in additional builds on same platform. Any repeated effort has me thinking templates/jigs. In the aviation world, we get strength and form using fiberglass. Something to consider (albeit a new skill) for things like the floor edges and step. once the mold is done, all future builds are quick and easy and can be done in any color or finish the customer wants.

[@EXPLORISTlife]

I'd love to learn how to work with fiberglass more. That would definitely open up a whole new realm of fixing 'weird corners' and such.

[@Spaceman-jo5mz]

Great job!

[@EXPLORISTlife]

Hey Spaceman 1111, Thanks so much! Cheers!

[@asfawaraya8498]

You guys are very good 👍

[@EXPLORISTlife]

Thank you! 😃

[@blackmarketbarber]

So cool!

[@johnhaines564]

Great floor!

[@EXPLORISTlife]

Thank you!

[@RedBatteryHead]

Nice floor panel. Using out of the box stuff is great. Would have been nice to use a small drawer under the step or a light.

[@williamhanna5224]

Excellent !

[@DP179DAD]

Your videos are spot thank you as far as flooring what is the total thickness and where did you purchase it and what exactly should I ask for once again thank you

[@whatsitaboutwithphilcraig6661]

Awesome guys 👍

[@EXPLORISTlife]

Thanks 🤗

[@themoabpearl5711]

Thanks for putting link to flooring in the description, and about 20 more times in the chat ;-). Has this floor passed the ski boot test? Asking for a friend. . .

[@michaeldyer8566]

Hi can you please tell me have you covered battery to battery charging for lithium batteries thanks for all your great video content ,

[@Sardar84]

its super amazing

[@EXPLORISTlife]

Thank you so much 😀

[@vintagegoldmusic6843]

Looks like a company made and fitted floor.very intresting.

[@EXPLORISTlife]

Thanks! 🙂🙌

[@ZebaKnight]

This is very helpful. I definitely won't be trying to "do it myself"! Also, I'll feel better about paying whoever _does_ insulate my van's floor. 😊

[@pattycakestunts6091]

It looks amazing 🤩!!! For a few weeks build !!! I love creativity and OSHA don’t need to know Nothing lol 😂

[@danielkopaee9241]

Agh the zip sheathing! Such a good idea.

[@EXPLORISTlife]

Yeah, super easy to work with.

[@danielkopaee9241]

@@EXPLORISTlife definitely! And much cheaper than priming Baltic birch like I did

[@danielkopaee9241]

Curious, why the wall and not the subfloor variety?

[@chargestate42]

You had me at CAD program ;-)

[@dansorensen7249]

Great video guys. Where did you source the L track from?

[@FRZNTYM1]

Nate those ridges on the floor you are referencing are stiffening beads just like we use on the roof when designing the bodies of these vehicles.

[@EXPLORISTlife]

Indeed!

[@craigj6277]

Nice job.

[@EXPLORISTlife]

Thank you! Cheers!

[@Geekchica]

Nate & Steph, you are so valuable to me as creators and as mentors! I can’t express how relieved I am to find your video on the flooring. In Spanish we say, “El Maestro aparece cuando el alumno está preparado.” Meaning, the Teacher arrives when the student is ready. I have been a subscriber to your channel for a couple of years, but NOW I am ready with my new-to-me van and ready to start the flooring process. Only difference is my van was a mobility van in its previous life; it hauled wheelchair-bound travelers. So, the van subfloor is steel plate welded to the van body. I’m going to sand off the rust, spray Rustoleum Stop Rust, then proceed as you did with the Zip system. I love your use of the waterproof sail fabric. Thank you, too, for identifying how to maintain access to the spare tire release. Thank you for your methodical, but not boring, explanations and excellent camera-work. You both are gems to me!

[@aurisnow]

Very cool! I built four Transits and your floor solution is amazing, using the L-track to secure everything was a great idea. You are def not afraid of labor intensive operations. Props!

[@EXPLORISTlife]

Yeah, this will definitely be the strongest, most robust, and most versatile way of attaching everything to the inside of the van we've ever done. Thanks for tuning in!

[@bigmikeswiss]

Clean work and precise execution. I would rather be hesitant, with the idea to add any passenger seats, for use during driving, to this kind of floor. There are reasons, why those in industrial produced cars, always are mounted to at least chassis welded mounting points. And not aluminium tracks with a few screws through iso-layer and nuts on chassis underside not even welded to be fixed sexurely. What about safety belts and their mounting-point geometry in regards to the seats and passengers? For guest-seats, only for usage when not driving around, there are light foldaway seats more practical and much less space consuming. As far my 5cts to a great project, eventually inspiring others to copy.

[@pwoens]

Awesome work, thanks for sharing and inspiring! Got my sheets Wednesday and all cut and set. Question - what glue/adhesive did you use to adhere the overlaps?

[@EXPLORISTlife]

Just general construction adhesive.

[@patrickmckowen2999]

Great floor👍

[@EXPLORISTlife]

Thanks! 🙂🙌

[@greggummere7449]

Beautiful finish detail, great explanations. Would it be possible to use something like a self-leveling product to fill in the gaps between the ridges on the original floor?

[@EXPLORISTlife]

Thanks! I think you'd have a hell of a time getting something to 'self level' on an unlevel surface like a van that naturally slopes to the front.

[@robertb4134]

i love the way you did the floor in that van, i'm going to do it same way , one question , what L-Track is that ? who makes that ? i like the way it drops in the channels and there's still some over hang on the sides , thank you in advance.

[@magdatomek]

Very nice pro tutorial. How do you like this floor material after use for a few months? Is it easy to clean, is the sand not penetrating , how about if is get wet, stain coffee, wine spill , mud, itc. Thank you

[@christosmaninos1570]

Nice Job

[@EXPLORISTlife]

Thank you! Cheers!

[@willjones5816]

Very helpful video. Gave me a lot of ideas. Was 3/8” insulation too thin? Hot knife seemed like way too much. I would think spray foam and then shaving it down would be less labor intensive and faster. Lastly-why not get bigger angle iron and cut it down to the right height rather than a second piece under the first?

[@ErikStenbakken]

Oh, yes. So much to copy here. So much. Thanks for sharing. I’ve watched a ton of flooring videos and there is always a major “I’d never do that!” And aside from wire knife shaving the spacers 😅 … this is my new plan!

[@EXPLORISTlife]

Haha! I felt the same about shaving the spacers even though bolting the L-Track down was definitely more time consuming. 😂🤣

[@mkevins07]

Hey Nate and Steph! Your content has been pivotal for me, so thank you so very much. I'm curious if you'd do this again, and specifically curious if the Polyiso/XPS is going to compress over time and compression set? Would you repeat it this way, or consider adding load bearing joists etc?

[@EXPLORISTlife]

Pretty much do it the same again, yeah.

[@computerjantje]

very nice. thank you for the video

[@EXPLORISTlife]

Glad you liked it!

[@crowlsyung]

Awesome video. Thanks for sharing :). Do you remember the diameter of the hole you cut out for the spare tire access? Doing the same now and I'm struggling to find a small enough marine deck plate for a 2.5" access hole I cut into my floor.

[@dennislittlefield]

Excellent video! What van seats will you be mounting in the van? I'm considering doing a similar install.