You should seriously consider creating a build thread of your own.
Agreed, at some point I'll spend the time to detail the build.
Did you use a router to cut slots in your floor insulation to clear the corrugations? That would save ~1/2" of space, but I envision it being difficult to translate the complicated corrugation pattern to the insulation.
I did, it just required some patience and measuring. I would not do it again though. I would just cut wood strips to fill the gaps. My entire floor assembly as it sits has theoretical effective R-Value of 7.498, Wood filler strips and 1" XPS would have net a theoretical effective R-Value of 6.706. With a temp Delta of 65 degrees I.e. inside temp 65 outside temp 0, the difference in BTU/hr to maintain that temp delta is 61. Womp womp, my heater puts out 2.2kw or 7,500 Btu/hr. Humans sleeping approx 275 BTU/hr.
People often misinterpret R-values.
- An un-insulated bare sheet metal floor with nothing else would have a theoretical effective r-value of .85, 20-gauge steel (.00009), Interior air film (.68) exterior air film (.17) This would require 4588 Btu/hr.
- Add a layer of 1/2 inch XPS and a plywood floor, total assembly R 3.82 (r-values are additive, previous un-insulated floor .85 plus half inch of XPS 2.35 and 1/2 inch plywood floor .62) and that heat loss drops to 1020 BTU/hr a 3568 BTU/hr savings!!! Yay that's a ton, 48% of my heater output.
- Add another 1/2 inch XPS (previous 3.82 plus 2.35) Total assembly=6.17 and the heat loss drops to 632 BTU/hr a savings of 388 BTU/hr. Huh, that's not much... 5% of my heater output.
- Lets go crazy and add two additional inches additional XPS. Total R-value of 15.57 and the heat loss drops to 250 BTU/hr a savings of 382 BTU/hr
R-values are the best real world example of the law of diminishing returns.
How did you attach the sliding rails for the bike drawer to the floor of the van?
Bolted through my floor assembly to rivet nuts in the van floor. Rigid blocking used all the way through the floor assembly so as to not compress the insulation when bolting down. The brackets are sections I cut from a long piece of this I purchased. 8020 45-8636 Structural Shape
I would have 8020 pre-cut them to length next time, $2.45 per cut is worth the saved labor of cutting the giant section of extrusion. All you would then need to do I drill the holes and relief holes for tool access. You could also use one of their pre-fabricated corner gussets. 8020 Gussets and corner brackets
just find the one that matches enough of the dimension you want each bracket has a CAD drawing with dimensions. I wanted my drawer slides flat on the floor so I made my own.