Floor planning

The floor install is still ahead, but the planning is done.

After the foam template fit on the first try, the next decisions were materials and the L-track system. Plywood thickness, insulation layer, track spacing, mortised flush versus proud mount.

The plan

Factory steel floor, then 1-inch rigid foam insulation, then 3/4-inch plywood finished with water-based polyurethane. L-track mortised flush every 5 inches, cross-grain, bolted through to the factory floor channels with stainless hardware and rubber washers.

The L-track spacing came from reading too many forum threads. Every 5 inches is probably overkill for how I’ll use the van, but it’s easier to skip a slot than to drill new holes later.

Why mortised flush

Because I’m walking on this floor and I don’t want to trip over raised rails. Also because a flush-mounted track disappears under a rug or mat when I’m not using the cargo tie-downs.

The tradeoff: mortising is more work than surface-mounting. Router, jig, multiple passes, dust everywhere. But the result looks clean and feels solid.

Next: first mountain run to Winter Park.