Terrific idea! I'm starting my van build and this flooring system is exactly what I was looking for as a light-weight solution. Liked and subscribed. Thank you for sharing! Looking forward to more of your videos.
Hi Pete. Your videos are exactly what I've been looking for, but unfortunately the TH-cam search just throws up video after video of people doing much the same type of build with very little attention paid to weight. I'm truly inspired by your videos, thanks a million 👍
Absolutely brilliant! There is a company out of Oregon who is doing something similar using a manufactured closed cell/fiberglass composite board and they use a CNC machine to cut out panels for people who are building out vans. They charge $2300 + shipping for the panels, and $5500 + shipping, for the panels with PEX tubing inserted for floor heating. Anyway, I searched the internet for the panels and they would also be expensive although a lot cheaper than getting them made and shipped. I was searching for someone who may have used these panels, and I stumbled on your video which is a brilliant DIY version of the same thing at a fraction of the cost. The fiberglass reinforced panel is suppose to be strong enough that you can get away with a 1/2” or maybe even a 1/4” plywood subfloor which reduces the cost and weight of the plywood as well. I see that you chose to forgo a plywood overlay to reduce height and any potential water damage situation.
Very unique and smart van flooring ideas! Wish I had found it sooner! Could you do use the same foam plus fiberglass combo for countertops and cabinets? Then paint it or cover them with wood veneer?
I suppose you could use foam and fiberglass for cabinets and countertops but it sounds like a lot of work. I only have a single cabinet in my van and the steel frame/drawer guides provide the strength so a light weight cabinet covering would be possible. Most of the wood I use is for the drawer faces on the lightweight drawers I describe in one of my other videos. I might look for lighter drawer faces the next time.
If you had the luxury of a high roof's interior height and you went with 1in thick XPS in the floor, would you use the same, single layer of fiberglass? Would you do two layers? Many thanks and continued good luck with the van!
If I had a high roof, I might go to 1" XPS for more insulation but I would again go with a single layer of fiber glass on both sides. So far the single layer of fiber glass has shown no failures. A second layer would add more weight for minimal increase in insulation and would double the amount of work spreading epoxy on the layers. If I have a floor failure in the future, I will report it.
@@fivepoundpete The strength and resistance to wear with only one layer simply amazes me. As someone with a 5 lb base weight as well, the efficiency and MPG savings excite me. I'm unsure if your build is finished, but I hope you recorded your MPG before and can check again after. Best of luck!
When the van was new and had 65 psi front and 75 psi rear pressure I got 20.1 MPG. After the build of 940 lbs and loaded with another 640 lbs of gear we took a 5000 mile trip to Vermont for the total eclipse. I had lowered the tire pressure to 57 psi all around for a better ride. We got a wild variation in MPG from normal conditions at 18 MPG to a high of 24 MPG and down to 14 MPG into strong headwinds in Kansas. These numbers were at high interstate travel speeds for an average of 17.5 MPG round trip. As you can see there are too many variables to gauge what the van build weight impact to MPG was. Overall I am pleased with the milage I am getting. The smoother ride and getting there quickly was well worth the impact to MPG.
Hey Pete, Love your channel that I just found. Had to sub and now I'm binge watching your content from the beginning. LOVE it! I'm Super impressed with this floor. High performance and looks great. Could you share your layup schedule, top and bottom? How many layers of glass, what kind of weave and how many oz. weight each sheet of glass?
I am a real novice when it comes to fiber glassing. I found the fabric on Amazon, Fiberglass Cloth, Style 7781-8 Harness Satin Weave, 60 Inches Wide by 5 Yards Long. I used a single layer on each side. I used TotalBoat-510825 High Performance Epoxy Kit, Crystal Clear Marine Grade Resin and Hardener (Gallon, Medium). These products seem to work for me and I had quite a bit left over. I suggest you have a helper that can mix up small batches of resin while you keep working to apply the resin, that way you end up with a more consistent application.
Actually for strength only the battery, refrigerator and passenger bench seat are bolted to the van's metal floor. Since there is not a plywood subfloor to screw to, all of the cabinets and the shower enclosure sit on the floor but are bolted to the walls.
You essentially made a simpler version of Coosa Board used in the marine industry. You can I fact bolt through it if needed with washers, but I’d add an extra layer of fiberglass in those spots to reinforce the spots if that was going to happen. Very well done and your use of the PVC reinforcement is a great idea.
I had never heard of Coosa Board, I learn about new materials from my viewer. Coosa Board while stronger would have cost over $700 compared to $400, been heavier and I still have fiberglass cloth and epoxy left over for other projects. I placed a base of 1/2" plywood under the electrical box and refrigerator to spread the weight to avoid compressing the foam core of the composite. The base also allowed me to place the holes in the floor where they would not hit brake lines and position holes where they aligned with the battery tie down straps and the refrigerator mounting holes.
Hi Pete. Thanks for this video! Im planning to exactly the same with my interior. It’s nice to see some kind of conformation that the ideas are somewhat not new and done by others. But im planning to use foam core and fiberglass for the rest of the interior aswel. Now im curious what made you decide to use other materials? And what are your thoughts on building an interior made our foam fiberglass? Please update on how your floor holds up Thanks again and cheers Eric
The goal for building my van is naturally to have a van that meets our requirements but also to experiment with new materials and ideas to make my van as light as possible and to share my ideas with other van builders. I am taking my passion for designing ultralight backpacking equipment (www.fivepoundpete.com/) and applying it to van conversions. I have had my fiberglass floor in my van for a year and a half. It has been in during the entire build process with hundreds if not thousands of trips climbing in and out of the van and shows no sign of failure. I have a low roof van and I wanted an insulated floor that didn't take up a lot of headroom and was light weight. My son suggested the fiberglass floor with the thought that if a surfboard could withstand the forces of an ocean wave it might be strong enough for a floor. So far it has held up great. With regard to building the interior with foam core covered in fiberglass I have seen another conversion trying the same solution, you might want to look it up. I would be concerned that it would be a very labor intensive and time consuming build.
@@fivepoundpete Well I can’t thank you and your son enough for your try in a Fiberglass floor. Im pretty inexperienced with Fiberglass, and as im planning my van build, im trying small little projects to learn from. And yes it is very labour intensive. So beside the design idea, of fiberglass only, im trying to keep an open mind for other materials and lightweight hacks. And like you, my attempt is to become lightweight as possible, as weight restrictions are really checked on by law enforcement, in Europe. It’s always a limitation on what you want to bring with you, in terms of luxury and convenience. But im hoping to reach the level which my family can all feel comfortable with. Thank you for the website you send, i will look soon, to catch some more ideas from you Cheers
The fiberglass has the thermal properties of a thin layer of plastic and does not add a significant amount of R value. It is there primarily for rigidity to spread any weight over a larger area.
Terrific idea! I'm starting my van build and this flooring system is exactly what I was looking for as a light-weight solution. Liked and subscribed. Thank you for sharing! Looking forward to more of your videos.
Glad it was helpful!
Hi Pete. Your videos are exactly what I've been looking for, but unfortunately the TH-cam search just throws up video after video of people doing much the same type of build with very little attention paid to weight.
I'm truly inspired by your videos, thanks a million 👍
Thank you. I hope you find some ideas in my videos to help you lower the weight of your van build.
Absolutely brilliant! There is a company out of Oregon who is doing something similar using a manufactured closed cell/fiberglass composite board and they use a CNC machine to cut out panels for people who are building out vans. They charge $2300 + shipping for the panels, and $5500 + shipping, for the panels with PEX tubing inserted for floor heating. Anyway, I searched the internet for the panels and they would also be expensive although a lot cheaper than getting them made and shipped. I was searching for someone who may have used these panels, and I stumbled on your video which is a brilliant DIY version of the same thing at a fraction of the cost. The fiberglass reinforced panel is suppose to be strong enough that you can get away with a 1/2” or maybe even a 1/4” plywood subfloor which reduces the cost and weight of the plywood as well. I see that you chose to forgo a plywood overlay to reduce height and any potential water damage situation.
The floor is working well with no problems after two years and 20K miles without a plywood overlay.
HI Pete!! So good to see you the other day. Love these videos....now I just need to find a van to build!
Good to see you too. Good luck on your search.
Hi Pete. Matt here from Clarity Off Grid. Love your floor! It’s beautiful!
Hey, thanks!
Fantastic! I'm using your system, been searching for some time now, just Love your thinking!
The floor has held up fine so far. Good luck on your van build.
Very unique and smart van flooring ideas! Wish I had found it sooner! Could you do use the same foam plus fiberglass combo for countertops and cabinets? Then paint it or cover them with wood veneer?
I suppose you could use foam and fiberglass for cabinets and countertops but it sounds like a lot of work. I only have a single cabinet in my van and the steel frame/drawer guides provide the strength so a light weight cabinet covering would be possible. Most of the wood I use is for the drawer faces on the lightweight drawers I describe in one of my other videos. I might look for lighter drawer faces the next time.
Awesome info thanks
Glad it was helpful!
If you had the luxury of a high roof's interior height and you went with 1in thick XPS in the floor, would you use the same, single layer of fiberglass? Would you do two layers? Many thanks and continued good luck with the van!
If I had a high roof, I might go to 1" XPS for more insulation but I would again go with a single layer of fiber glass on both sides. So far the single layer of fiber glass has shown no failures. A second layer would add more weight for minimal increase in insulation and would double the amount of work spreading epoxy on the layers. If I have a floor failure in the future, I will report it.
@@fivepoundpete The strength and resistance to wear with only one layer simply amazes me. As someone with a 5 lb base weight as well, the efficiency and MPG savings excite me. I'm unsure if your build is finished, but I hope you recorded your MPG before and can check again after. Best of luck!
When the van was new and had 65 psi front and 75 psi rear pressure I got 20.1 MPG. After the build of 940 lbs and loaded with another 640 lbs of gear we took a 5000 mile trip to Vermont for the total eclipse. I had lowered the tire pressure to 57 psi all around for a better ride. We got a wild variation in MPG from normal conditions at 18 MPG to a high of 24 MPG and down to 14 MPG into strong headwinds in Kansas. These numbers were at high interstate travel speeds for an average of 17.5 MPG round trip. As you can see there are too many variables to gauge what the van build weight impact to MPG was. Overall I am pleased with the milage I am getting. The smoother ride and getting there quickly was well worth the impact to MPG.
Hey Pete,
Love your channel that I just found. Had to sub and now I'm binge watching your content from the beginning. LOVE it! I'm Super impressed with this floor. High performance and looks great. Could you share your layup schedule, top and bottom? How many layers of glass, what kind of weave and how many oz. weight each sheet of glass?
Mad respect for what you've got accomplished so far and can't wait to see what else is coming. Props! 😎 Thanks.
I am a real novice when it comes to fiber glassing. I found the fabric on Amazon, Fiberglass Cloth, Style 7781-8 Harness Satin Weave, 60 Inches Wide by 5 Yards Long. I used a single layer on each side. I used TotalBoat-510825 High Performance Epoxy Kit, Crystal Clear Marine Grade Resin and Hardener (Gallon, Medium). These products seem to work for me and I had quite a bit left over. I suggest you have a helper that can mix up small batches of resin while you keep working to apply the resin, that way you end up with a more consistent application.
I assume that all cabinets and accessories will have to be either screwed or bolted to the van's metal floor?
Actually for strength only the battery, refrigerator and passenger bench seat are bolted to the van's metal floor. Since there is not a plywood subfloor to screw to, all of the cabinets and the shower enclosure sit on the floor but are bolted to the walls.
You essentially made a simpler version of Coosa Board used in the marine industry. You can I fact bolt through it if needed with washers, but I’d add an extra layer of fiberglass in those spots to reinforce the spots if that was going to happen. Very well done and your use of the PVC reinforcement is a great idea.
I had never heard of Coosa Board, I learn about new materials from my viewer. Coosa Board while stronger would have cost over $700 compared to $400, been heavier and I still have fiberglass cloth and epoxy left over for other projects.
I placed a base of 1/2" plywood under the electrical box and refrigerator to spread the weight to avoid compressing the foam core of the composite. The base also allowed me to place the holes in the floor where they would not hit brake lines and position holes where they aligned with the battery tie down straps and the refrigerator mounting holes.
Hi Pete. Thanks for this video!
Im planning to exactly the same with my interior.
It’s nice to see some kind of conformation that the ideas are somewhat not new and done by others.
But im planning to use foam core and fiberglass for the rest of the interior aswel.
Now im curious what made you decide to use other materials?
And what are your thoughts on building an interior made our foam fiberglass?
Please update on how your floor holds up
Thanks again and cheers
Eric
The goal for building my van is naturally to have a van that meets our requirements but also to experiment with new materials and ideas to make my van as light as possible and to share my ideas with other van builders. I am taking my passion for designing ultralight backpacking equipment (www.fivepoundpete.com/) and applying it to van conversions.
I have had my fiberglass floor in my van for a year and a half. It has been in during the entire build process with hundreds if not thousands of trips climbing in and out of the van and shows no sign of failure. I have a low roof van and I wanted an insulated floor that didn't take up a lot of headroom and was light weight. My son suggested the fiberglass floor with the thought that if a surfboard could withstand the forces of an ocean wave it might be strong enough for a floor. So far it has held up great. With regard to building the interior with foam core covered in fiberglass I have seen another conversion trying the same solution, you might want to look it up. I would be concerned that it would be a very labor intensive and time consuming build.
@@fivepoundpete Well I can’t thank you and your son enough for your try in a Fiberglass floor.
Im pretty inexperienced with Fiberglass, and as im planning my van build, im trying small little projects to learn from. And yes it is very labour intensive.
So beside the design idea, of fiberglass only, im trying to keep an open mind for other materials and lightweight hacks.
And like you, my attempt is to become lightweight as possible, as weight restrictions are really checked on by law enforcement, in Europe.
It’s always a limitation on what you want to bring with you, in terms of luxury and convenience. But im hoping to reach the level which my family can all feel comfortable with.
Thank you for the website you send, i will look soon, to catch some more ideas from you
Cheers
Good luck on your search for more lightweight ideas and materials.
did the fiberglass add any R value or was it just for rigidity?
The fiberglass has the thermal properties of a thin layer of plastic and does not add a significant amount of R value. It is there primarily for rigidity to spread any weight over a larger area.