How to Install a Van Subfloor

Updated on February 15th, 2021

The first major step in our van build was installing the van subfloor.  We managed to complete the install in one day, but be prepared to have to wait overnight for any adhesive to cure before moving to the next step.

Please note: we made the decision not to insulate our floor. You can find out why in our van insulation post, but if you are planning to insulate your floor you will want to do that before you lay down your subfloor, and you will likely have to use a different method than the one laid out below.

Disclaimer:  In the interest of transparency, please be aware that this post contains affiliate links and any purchases made through such links may result in a small commission for us at no cost to you.

Tools needed for Van Subfloor:

• Jigsaw with blade assortment
• Saw horses
• Sharpy
• Gloves (we love these black nitrile heavy duty ones!)
• Screw Driver
• Caulk Gun
• Straight Edge
• Speed Square
• Cardboard Pointer
• Heavy Stuff
• Shop-Vac

Supplies Needed for Van Subfloor:

• 3 sheets ⅜ sanded plywood
• Adhesive–Loctite Power Grab Express All-purpose (4 tubes)

Create a Template of the Floor

We were lucky enough to have the van come with a rubber mat that we could use as a template.  We trimmed it down including trimming around any high spots like adhesive lumps or welding bumps.  If you are not so lucky, you can use cardboard or kraft paper.

Scribe Around Doors, Wheel Wells, and Any Other Weird Spots

Because it is really difficult and time-consuming to get a template to fit perfectly, we recommend using the pointer technique described in the video around 0:56, mark the template with a marker.  You will need at least two points of reference for any straight lines and as many as you want for curved surfaces. You really can’t have too many. We planned to leave a ¼” gap between the subfloor and vertical surfaces.  This can be eyeballed while scribing or you can do what we did and have to trim five different times.

Cut Plywood to Fit Template

Lay your template on the plywood.  If you watch the video you will see that we were lucky that the first template we used was basically symmetrical but don’t take chances.  Make sure you mark which side of your template is up and transfer your scribe marks onto the finished side. Line the template up with as many factory edges as possible.  Those fancy lumber robots will have cut a much straighter line than you’re capable of with a jigsaw. Transfer your scribe marks onto the wood. Use a straight edge to connect the straight lines and you may need to take a little artistic freedom with curved edges.

Using the jigsaw, trim around your marks.  Do it safely. With your hands out of the way.  Wear your safety glasses. Do as we say, not as we do.

Test Fit the Pieces

Put the cut pieces in the van to make sure they will fit.  If they need a little trimming, mark them with the marker and put them back on the sawhorse. Repeat until everything fits the way you want. This could take a few attempts.

Glue the Pieces in Plywood in Place

Using construction adhesive, glue the pieces in place.  Put glue down all of the floor ribs and make little spacers for the larger flat spots so they don’t dip. Glue the spacers to the floor and the subfloor to the spacers.  Once you’ve got a decent amount of glue down, drop those plywood pieces into place. With the Loctite you’ve got about 15 minutes to make adjustments if needed.

Weigh Down the Plywood

Find all the heavy stuff in your garage (attic, basement, neighbors garage, etc) and put it on top of the plywood.  Be careful to make sure the corners and joints are weighed down.

Let Cure Overnight

Grab yourself a beer, high five anyone in the vicinity, and kick your feet up. You’ve finished the subfloor!

Estimated Active Time:  6 hours

Estimated Total Time:  24-48 hours

We’d love to answer your questions!  Comment below and we’ll help!

For the next step in our van build, head over to our How to Install Van Insulation post.

For more posts related to the van build check out our Van Build Page.