Let’s talk flooring for my van. For a kayaker, water is a major concern that would eventually equal mold which would equal being sick all the time. Therefore, I did my best to do my research but I won’t know if what I did is correct until time passes.
Let me back all the way up. Astro’s tend to have issue with their fuel pump therefore I wanted to think ahead since I was ripping everything out. After some research, a hole was cut into the floor of the van right over the top of the gas tank. Super scary to have sparks flying with the cutting of metal over top a gas tank! (For reference, I did not cut this. I was chicken. I just measured and Nate cute where I drew out).
Once this was done, this acts as an access point so if I ever have issues, I don’t have to drop the entire tank. I can just access from the top and replace what I need to replace. I hope I never actually have to use this but better safe than sorry.
I added some sound dampening to the floor boards. Not sure if this helps or not but for the price, I don’t regret doing it. I then templated the floor out and went about cutting the plywood. Luckily, I could use one piece and then piece together the sides. I then add Kilz to all pieces of the ply. While this may not be necessary, I wanted the added protection with the chance of moisture. I added a couple coats which in turn took a couple of days.
To attach to the floor of the van, I used stainless steel metal screws. Reason being, I didn’t want them to rust from moisture on the underside of the vehicle. I was constantly checking before adding a screw to make sure I was not screwing into something else. I also countersunk all my screws since I needed to install flooring on top of this. I made sure to cut out the access door for the fuel tank. I drilled a big hole in the one side so I could get a finger in to actually lift this piece out if needed.
I do not have any close up photos of this but where the ply meets the wheel walls, I added clear silicone sealant that I purchased at home depot. I added a ton because I did not water trapped anywhere!
I then installed “luxury” vinyl planks from home depot. From my research, this seemed like the best choice. Waterproof, low maintenance, etc. (after time and using the floor, they lie. It scratches like crazy! I am throwing in and out of kayaks constantly though) This was my first time installing but incredibly easy. Just read the instructions that come with yours as some are installed slightly different. Make sure to have a piece of wood and rubber mallet on hand to knock pieces together. My job was a bit trickier due to the access door for the fuel tank but all in all, super easy project.
Sorry I don’t have a final picture of the floor but you will see it in future posts once I write about the bed I installed.