Maybe the foam board will compress some to “even out”?

Yes, enough IMHO.

Not aware of anything that's an exact fit.

If you REALLY want it perfect you could run the foam or plywood strips through a planer.... wouldn't take too long.

 

If you're wanting to maximize R-value and minimize height issues, and desire some compactness, I think Minicell foam is your best bet.

 

I ended up buying a marine grade piece of 3/8 inch plywood ($90 yikes) only to rip into many strips on a table saw. I then glued those strips to the van floor using construction adhesive. I figured 3/8" plywood + a little glue will perfectly match the height of the corrugated floor, and it does. I went with Marine grade plywood for it's durability if ever exposed to moisture and it's 7 ply which should provide enough meat to hold a screw. Only time will tell.

I did this on saturday and the glue is still curing under weight. The next step is putting a layer of 1/8 MLV, then 1/4 plywood screwed into the strips, and finally the vinyl top layer. I went with a coin-mat vinyl that I cut to size out of a 7.5 x 17 foot roll.

My goal was to create a low profile floor that provides a quiet ride.

My installation is very similar to morey's which is documented on his website (thanks Morey!).

 

The next step is putting a layer of 1/8 MLV, then 1/4 plywood screwed into the strips, and finally the vinyl top layer.

I too am trying to keep a low profile floor and am curious as to how the 1/4 plywood works for you. I haven't considered that option. Also, I like the idea of using MLV! Any ideas on where to get a good deal on that? I just read where another forum member removed the felt backing from the stock vinyl floor...would this essentially be MLV? If this would provide similar sound dampening as 1/8 MLV, I may go this route..and it is already cut!

 

Thanks for the input! Good to hear that the foam board will compress enough to even out. It seems like that would be the easiest material to use. Especially since I am not planning on screwing the plywood subfloor down. Although I will have to look into the Minicell foam option!

Regarding the marine grade plywood, I'm not sure that I would be able to find that locally.

 

Will have to dig thru paperwork to find foam source, most stuff through amazon but not it. Possibly "Foam Factory"...

'Painted' metal.

Not familiar with characteristics of stock mat - MLV 1 lb./sq

 

you can always stack 1/8" laminate flooring underlayment foam.

 

Pink insulation panels come in 1-1/2 or 2 inches thick. That stuff could be ripped on a table saw, to get strips 3/8 inch thick.

 

Great ideas with the underlayment stacking and insulation panel ripping! I also found this on Tractor Supply website I might have to give a look. https://www.tractorsupply.com/tsc/p...com/tsc/product/rb-rubber-multi-mat-rolled-rubber-3-8-in-thick-sold-by-the-foot

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The more I think about it, the more I really like EddieZ recommendation of ripping foam. Looks like the spacing between ribs are about 1.5" and 4". I could get a sheet of both 1.5 and 2 inch thick foam panels and rip to size!

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Bandsaw works well if you don't have a foam cutting heat saw.

 

I do have a band saw, but not sure I'd be able to keep a consistent width. Would it not cut well with a table saw?

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It might cut ok with a tablesaw, I haven't done it. Can't you clamp a 2x4 as a fence on your bandsaw?

 

Hmm..yeah I guess that would work. I'm having a hard time believing that I could keep a consistent 3/8 thickness that way though. I'm going to look a little harder for a material that will work (ie. 3/8 thick and hydrophobic), or just go with slightly taller rigid foam.

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Ripping foam as thinly as you are proposing is PITA. Start with something the right thickness and spare yourself. ...or not.

 

It seems to me that the 1/2 rigid cheap foam should compress nicely. Don't get the denser purple/yellow/pink kind, just the foil on one side white kind.

 

I went by Lowe's on my way home to see what they had as far as insulation goes. They have half inch Polypro which is foil lined on one side and very squishy. It is a rather large cell foam that is much like the styrofoam in disposable coolers. While I think it would work it only seems to compressible. In fact the three-quarter inch I'm able to easily compress in half with my fingers. They also had half inch R-max r matte plus-3 which is foil lined on both sides and a much smaller closed cell foam and still compressible, much more compressible than the more expensive closed cell foam. It's only about $11 for a 4 by 8 and I really think it'll work well. I'll check back in after I buy sheet and let you know how it fits.

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that's the stuff I was talking about.

 

I use a very sharp knife with a thin blade and a long straight edge. I've done beveled cuts by using a block of wood to set the angle of the knife blade. Note, the knife's cutting edge must be beveled to both sides, not just sharpened from one side. This makes it easier to cut a straight line.

 

I'm planning to install cork planks floor and have the same question about ribs.
Planks are about 3/8 think and I'm trying to save height.
I'm wondering would 3 layers of 1/8 cork for rib valleys, plus 1/8 cork undergarment layer on top of entire floor work to install planks on it?
Would it work without layer of plywood? Probably I'll glue some wood blocks in places where no ribs and wide valleys, because I guess cork alone might be too soft?

 

I had the same issue and decided to use 1/2" poly board and used adhesive sound deadening material on top of the 'bumps' which are now flash with the foam. I plan to glue a 1/2" plywood on top of that and then laminate or cork. I need headroom and don't care too much about floor insulation. Saw some people use 2" of foam board etc. I live in the Northwest so temps don't drop too low.

 

I’m doing three eights inch mini cell in strips in the valleys, and then a whole sheet of 3/8 inch mini cell on top of that. The ridge height is actually .4 inches, not .375, but close enough. I’m doing half inch plywood on top of that, but you could probably get away with 3/8 inch without noticing any dips. If you were doing cork plank I’m guessing it would appear uneven. So my total floor height above the ridges is 7/8 of an inch.

 

I put 1/2" closed cell foam in between the floor corrugations. Covered that with 1/8" MLV. 1/2"plywood on top of the MLV. Figured the closed cell foam would compress about 1/16".


More floor details:

https://www.ortontransit.info/floor