Vauxhall Vivaro Campervan Conversion - Pt 1 - Clean up and Sub Floor

This is my Vauxhall Vivaro Campervan Conversion series. Every step of the build will be detailed in this camper conversion. This is my second self build van conversion and this time its a LWB Vivaro. I find the whole van life thig very appealing and in this build I want to share as much of the van conversion process as I can. Hope you enjoy the videos series.

[@dalem1140]

Just bought exactly the same van. Lwb in silver. 2015 Sportive model so these vids are perfect 👍

[@dave-watson]

I just got a 2016sportive silver too. I'l going to start converting it soon and Ipost new videos as I go. Good luck with your conversion work.

[@jamiemiles5127]

I found you from your last conversion, I’m so happy I did I want to make a vivaro too next year, your really helping me understand what I need. Thanks man!

[@dave-watson]

I'm glad the videos help, this is the idea of youtube, to share knowledge and ideas. Thanks for watching.

[@jimmalone-kd1ce]

I'm new to your channel researching a refit to my T2 van. Your videos are superb. Thank you for sharing your knowledge and skills.

[@dave-watson]

Hi, My pleasure hope you find the videos useful and good luck with your refit.

[@christophernation4793]

Back with you as the Movano 3.5 T is sold and I now have a Reno Trafic LWB aka Vxl Vivaro. Was a fruit n veg grower's van [market stalls?] so a muddy cab. Shelving removed - hundreds of screws 5mm- 120mm. Floor up next, thus strarting with you again on Pt 1. I did find, with the Movano floor, bottom layer of 13mm ply, that wedged in around the sides, the step up to the cab, wheel arches etc, no need to screw it down. It didn't move a mm. Reflective dbl sided bubble on that and another layer of 9mm ply, which I screwed down into the bottom ply. This caused some mirth - well I saw the funny side - when I was stopped in the middle of La France Profonde by Customs/Police, empty van having done a removals run to Spain. Looking for drugs, they searched the van. Then a police officer decided to look under the flooring. I had but my Swiss Army penknife, with which this office tried to remove the well countersunk screws. Having failed to remove even one screw, she gave up.

[@scottjones9362]

I had little interest in this type of video until I stumbled upon it earlier. I can't wait to follow the whole conversion now! Well done Dave. Excellent production.

[@dave-watson]

Thanks very much. I think there will be about 16 videos by the time I've finished. Thanks for watching

[@scottjones9362]

@@dave-watson I found your channel this morning and I just watched the 6th! Looking forward to the problem solving for the next 10!👍🏼

[@christophernation4793]

When I came to remove the original ply floor of my Vaux Movano [Reno Master] I went round taking out the screws, as you do. Giving a mighty heave nothing moved. Using brute force and a jemmy I broke out a piece. I found that the whole thing had been screwed down by screws coming UP through the steel floor! I can't imagine why the original owners, a flower shop in Newport, Wales, did this. I had to break out patches of ply around these screws until I was able to isolate each screw and chivv it away with the a/grinder. I was pleased to find that the floor was nice and clean - given it had dozzens of screw holes in it.

[@dave-watson]

Hi Chris, That certainly is a strange way to screw the floor down, they must have had it up on a ramp or lift. Thanks for watching.

[@d_s_ctube]

Great job. I'll be doing similar soon so this is VERY helpful.

[@dave-watson]

Thanks a lot. Good luck with your own conversion, hope the videos help.

[@RaspingLemon]

Hey Dave, i found you through your last van conversion, this one was incredible so far, the filming and editing was fantastic. You've clearly put a lot of effort into this one, can't wait for the next one.

[@dave-watson]

Thank you very much. The new build is coming along very well. I'm going to try to post a video every Sunday.

[@jacobgudgeon646]

Great video Dave, looking forward to the next one!

[@dave-watson]

Thanks a lot. I'm going to try to post a new one each week on Sunday.

[@johnholdroyd6243]

I’ve just bought this same van same colour also LWB I’ve subbed to you as am useless when it comes to DIY lol great video 👍

[@dave-watson]

Thanks John, I hope the videos help. Many more to come. And good luck with your conversion.

[@leehodgetts4006]

Hi Dave, Thanks for the video. We’re just about to start our Vivaro build.

[@dave-watson]

Thanks, I'll post a new video each week to show the progress. Good luck with your own conversion.

[@nunofilipe2071]

Great job. Best Regards NUNO Portugal

[@dave-watson]

Thanks a lot Nuno.

[@christophernation4793]

Dealing with these screw holes was rather unconventional. I had a sizeable tin of white Hammerite on the shelf over the cab, which faces rearward. Going over a particularly big bump the tin shot off the shelf and burst open on the floor. Fortunately there was nothing on the floor other than spilled Hammerite so I sacrificed the indoor broom by brushing the Hammerite out all over the floor. The result was perfectly satisfactory. Paint went into the screw holes. A job got ticked off the list.

[@TK_CUTS]

Love the content mate 👍

[@dave-watson]

Thanks a lot, hope you enjoy the whole series.

[@Liam-xp1do]

Dave, a huge thanks from me for this video. Excelleny explanations and reasoning for doing what you have. Cant express enough how great this video is for me as a first timer converting a similar build van! Curious as to what depth the wood is in the cornered areas to level out eith the metal ribs? Also would you sound proof and insulate the wheel arches had you had more material to do so? Thanks again!

[@dave-watson]

Hi Liam, I did the wheel arches with the same material that is on the floor but in a later video. I used mainly a 18 x 28 from wickes. Hope the rest of the videos help and good luck with your conversion.

[@Liam-xp1do]

Hi Dave, thanks again for you videos - a huge help. Wondering how you deal with the side door step area? I've kept my subfloor the whole size and haven't cut out the step yet. Not sure how to tackle this and can't find much online - wondering if you have any bright ideas? Thanks again, hope you're enjoying your van!!

[@dave-watson]

Hi, I made a cut out in the sub floor where the step is and then put some carpet on it and the original plastic step back on. Otherwise it's a much higher step up into the van.

[@bobnicholls]

Loved your last van, looking forward to watching this series. Ref drilling/screwing through the floor, do you get underneath and treat each one with rust prevention & silicone?

[@dave-watson]

Hi bob, I don't treat the screws under the van. Many of them are above other components live the fuel tank etc. But the screws themselves are stainless steel.

[@andrewcornford2306]

I've got the 2008 LWB high roof, converted it 7 years ago, I can never understand why people use flat tops for van conversation.

[@JHA854]

Because if you’re like me and live in a flat with underground parking, you can’t go over two meters. Also restricts how many car parks you can get into. Many beaches have a 2 meter height limit to stop campers. My van is just under that with solar and a roof window, so I can go anywhere.

[@pumasek]

Hi dave! What is the thickness of the foam on the floor? Is this enough or would you choose a thicker one if you were building it again?

[@dave-watson]

If I remember correctly the foam was 10mm. It seemed okay and it also had the 11mm OSB and then laminate flooring.

[@renaulttraficconversion]

Excellent job, Dave. Is that flooring waterproof? If not, I suggest you use a sealer. I will look at the remaining videos. You may have done this. Have a nice day.

[@dave-watson]

Thanks, The OSB3 is moisture resistant and makes a great sub floor.

[@fransvanlife]

Good evening Dave, love your videos, I've got a Vivaro that I am about to start converting but I have a question about the sub floor. I was going to go down the batten and celotex flooring method but am about potential condensation, I see in your video you use the sticky back foile rubber matting, is the foil aspect of it the vapor barrier? I was going to stick my batten to the floor with flexible adhesive as I don't want to screw through the base of the van and create possible water Ingres points. Am I thinking to much into this ? I would be sealing the batten/celotex with foil tape but am worried the underside could make condensation 😔😔😔😔 sorry for the long comment but it's the start of the build and I don't want to do it wrong from the off.

[@dave-watson]

Hi Frances, I used the sticky back closed cell foam on the floor to save some height in the finished van. The battens and celotex take up more space and leave you with less height. And yes the foil on the back does act as a vapour barrier once it is all taped up. But with this method you would have to screw the wooden sub floor into the van. It's always a matter of compromises. If you can get away with the less height the celotex would be the way to go. Hope that helps and thank very much for the donation.

[@mariagillinson8527]

I’m in Canada and curious to know how much it cost to buy the van in the UK and what other out of pocket costs ?

[@dave-watson]

I depends what you but mut a good low miles vivaro will cost between 10 - 13k and about 4 -5k for the conversion materials

[@chatteyj]

I've been debating whether to get a vivaro to convert but with the current insane prices I'm not sure i can justify it, things are almost double in price what they were two years ago.

[@dave-watson]

I know the prices have gone up a lot but there are still good deals to be had, and its a great project to do.

[@jonnyrigby9486]

big up dave

[@dave-watson]

Thanks a lot

[@davidmilanovic4825]

Started my first ever conversion and sticking to your videos mainly! :) Was just wondering, is that thin insulation on the floor enough? UK based too, but from what I've seen, most other UK converters put thicker insulation on the floor. I'm a whimp, hate sleeping in cold.

[@dave-watson]

Hi David, I went for the thin closed cell foam insulation on the floor for the height. I've seen people using the 25mm board insulation but that reduces the headroom quite a bit. Good luck with your conversion hope it all works out.

[@deanmg98]

Hi Dave, love the videos. Once the self tapping screw hits the floor of the van, what length would you advise the screw to go beyond that point? Just wondering as for when you consider the insulation and flooring thickness, if I add your recommendation to the thickness, it’ll give me the screw length required. Appreciate any help.

[@dave-watson]

Hi Dean, Glad you are enjoying the videos. The self tappers for the floor were 25mm, that's enough to get through the 11mm USB and the insulation (as it is compressed by the floor and the screw) so it will go through the rib of the floor by about 8mm, which is less than the depth of the rib. Anything longer might hit some of the components under the van. So I would go with no more than 25mm. Hope that helps.

[@deanmg98]

@@dave-watson that’s fantastic Dave. Thank you so much. It’s very much appreciated.

[@joeryanisaocelot]

Hi Dave great videos. I'm working on a similar build and find this series very helpful. I was just wondering in terms of screwing down the floor, how were you able to drill into the floor of the van without worrying about perhaps nicking anything important on the outside bottom of the van?

[@dave-watson]

Hi and thanks for watching the videos. For the floor I measured the thickness of the board and the insulation and the depth of the ridges on the floor and then got some screws which would not go beyond the underside of the ridges. Also I drilled with the bit only sticking out of the drill be the same amount as he screw. It all worked out fine, but I did also look under the van first just to see if there was anything I might hit. Sorry that's a bit longwinded but so long as the screws are not too long it should be okay.

[@joeryanisaocelot]

@@dave-watson thanks for the response! That's some great advice, have been scratching my head about how to get this done in a way that's not too risky. Cheers again

[@katicus_prime]

what length self taping screws did you get to screw the subfloor in to the ribs of the van please ?

[@dave-watson]

Hi. I used 28mm self tapping screws to get through the sub floor, insulation and the ribs on the floor of the van. Thanks for watching

[@daireharlin181]

This chap looks like Frank from US shameless

[@abikerstale806]

Yes Dave, Great... going to be watching - Subscribed... - you might like my conversion or ideas? Hope all goes well!

[@dave-watson]

Thanks a lot, I just subscribed to your channel, good luck with your build.

[@jasonpugz]

Hi , you have a link to the insulation you used for the floor ? Also will you be using the same stuff for the rest of the van.? Thanks.

[@dave-watson]

This is the place I got the insulation from www.ebay.co.uk/usr/campervan-insulation-co-uk?_trksid=p2047675.m3561.l2559 hope that helps. It seemed like good stuff.

[@jasonpugz]

@@dave-watson thanks Dave will you use that insulation for the whole build ?

[@dave-watson]

@@jasonpugz No, I'm using the shredded up plastic bottles for the walls and roof. I think the next ideo is about the insulation.

[@Hwslynch]

Hi Dave, what size screws did you use? I am starting the exact van and exact spec. Regards Alex

[@Hwslynch]

Also where is the insulation from? Do you have product name please?

[@dave-watson]

Hi Alex, I got most of the insulation off ebay, a search for "Closed Cell Foam Insulation" should find it. I think I used the 28mm elf tappers from B&Q for the floor. Hope that helps and good luck with your van. Oh by the way I will be uploading a materials and costs video next week.

[@user-pi9nh1qw6g]

Hi are you still making rock n roll beds

[@dave-watson]

Hi, Yes I do still make the wooden rock and roll beds but I can only do local pick up as a couple I sent with couriers arrived damaged. I'm at NE33 postcode if you are local drop me a message if you want one. Thanks for watching.

[@russfoggan4092]

You like the Vivaros Dave?

[@dave-watson]

I do. Really nice van to drive and a bit bigger than the VW Transporters.

[@stevebroadway7274]

Problem with the vivaro is they are rubbish and breakdown , blow up , even the AA gave up on them

[@dave-watson]

I've not had one blow up yet and I'm on my 6th, there can be problems with the DPF, but I like them.