First Construction Task Completed!

Everything I have done with Ansel up to this point has been preparatory.  Now I have completed the first actual construction task...the sub-floor!!

This wasn't a difficult task, and it really didn't take too long.  What really helped was the rubber floor mat that was in the van when I bought it, which I was able to use as a template for the 3/4 inch extruded polystyrene (XPS) insulation.  Otherwise, I would have had to make my own template out of cardboard and do a fair bit of custom-fitting.

Couple pieces of cut XPS.  The rubber floor mat is visible in the foreground.

I was then able to use the cut pieces of insulation as templates for the 5/8 inch plywood that would comprise the actual sub-floor.  I cut 3/8 inch lap joints in the plywood so that I could glue and nail the seams, giving the sub-floor a bit more stability.

Lap joint in plywood.

Once I had everything cut and test-fit, I was ready to start gluing down the floor assembly.  I knew I needed more adhesive, but I thought the one tube I already had would be plenty to at least get the insulation down.  Wrong!  I got the biggest insulation piece glued down and was starting to lay down the glue for the adjacent piece when suddenly the tube went dry.  Crap.  I couldn't stop now since the adhesive would soon set up.  So off to the hardware store I went.  I decided to buy the contractor size tube, which was equivalent to nearly 3 smaller tubes, thinking this would be enough to complete the entire sub-floor.  Wrong again!!  I finished gluing the insulation down and started gluing down the plywood when I ran out of adhesive again.  So back to the hardware store.  This time I bought extra adhesive just in case, though in the end I didn't need it.  Fortunately these two missteps didn't cause any major issues, though I did have to use a pry bar to get the last board to slip into place as the adjoining board had begun to set.  Some brad nails in the lap joints, and I was done with the very first task!  That's what I'm talking about!!!

When I get back from our family vacation (which is where I am writing this), I will cut in the galley side window and the roof ventilation fan.

The templates were very helpful in cutting around the wheel wells due to the curves.

Some additional curved edges where a template is necessary.