UNAKA GEAR CO. TURNKEY COOSA BOARD INSULATED FLOORING SYSTEM

UNAKA GEAR CO. TURNKEY COOSA BOARD INSULATED FLOORING SYSTEM

At WEST COAST VANS, we know that building a bulletproof foundation inside a camper van has traditionally been one of the most labor-intensive, frustrating stages of a custom build. Upfitters are usually stuck tracking down heavy plywood sheets, hand-scribing complex wheel well radiuses, and drilling dozens of holes straight through the factory sheet metal—only to deal with chronic floor squeaks, structural thermal bridging, and trapped moisture that triggers rust underneath the rig. Even worse, many builders make the mistake of using residential snap-together vinyl planks, which inevitably buckle, warp, and separate under the extreme temperature swings inside a vehicle. We believe your subfloor should be completely rot-free, hyper-lightweight, and ready to abuse. Enter the Turnkey Van Flooring System—the ultimate high-performance thermal, acoustic, and structural flooring solution. This completely engineered assembly combines CNC-precision cutting with advanced fiber-reinforced foam and commercial marine sheet vinyl, delivering an absolute pro-level layout that glues directly down to your factory ribs without a single chassis-penetrating screw. Ask Us Product Questions Anytime if you want to coordinate your cabinet anchoring points or choose a custom commercial-grade top layer!

WCV EXPERT TIP Maximizing the utility of your extended roof area starts with strategic component spacing before you drop in your final layout. Pro Tip: Because this turnkey system uses high-tech 1-inch Coosa Board sheets, it glues directly down to the factory metal floor using a high-strength polyurethane adhesive. This completely eliminates the need to drill self-tapping screws through your van floor, permanently protecting your chassis against under-rig rust and water intrusion. When choosing your final top wear layer, we strongly recommend opting for textured, embossed finishes like Lonseal Loncoin or Lonridge. These marine-grade, commercial sheet vinyl options handle heavy beach sand, muddy boots, and wet dogs without scratching, expanding, or creating the annoying seam gaps common with residential vinyl planks.

PRODUCT OVERVIEW The Turnkey Van Flooring System is an advanced, commercial-grade interior architectural subfloor and finished wear-surface matrix built for van lifers who demand elite thermal retention and acoustic deadening. Shunning heavy, moisture-absorbing plywood, this premium system is centered around 1-inch structural fiber-reinforced foam panels that cut subfloor weight completely in half while delivering an impressive R3 insulation factor. Arriving fully CNC-machined alongside a sleek, black powder-coated steel perimeter trim kit, this comprehensive upgrade allows you to take your van floor from bare metal to a fully sealed, retail-finished foundation in less than two hours.

BEST FOR

• WEIGHT-CONSCIOUS DIY BUILDERS: Perfect for overlanders looking to shave hundreds of pounds of dead weight off their gross vehicle weight rating (GVWR) compared to standard plywood floors.

• FOUR-SEASON CLIMATE CONTROL: Ideal for winter skiers and desert campers who need a true thermal break to lock out freezing sub-floor drafts or intense highway road heat.

• CUSTOM EXPANDED CABINET LAYOUTS: Designed for builders who want to extend their galley kitchen cabinets past the traditional sliding door boundary utilizing an integrated structural step extension.

TECHNICAL SPECIFICATIONS

• CABIN STORAGE PROFILE: Advanced turnkey thermal-insulated and sound-deadening subfloor system

• SUBSTRATE CORE MATERIAL: 1-inch Coosa Board structural fiber-reinforced high-density foam

• WEIGHT EFFICIENCY INDEX: Nearly 50% lighter than traditional plywood subfloors with 3x the structural strength

• THERMAL RESISTANCE RATING: Built-in R3 insulation factor for maximum vehicle climate stabilization

• FINISHED WEAR LAYER: Premium, commercial marine-grade pre-cut sheet vinyl surface protection

• PERIMETER ENCLOSURE TRIM: Heavy-duty, CNC-formed steel trim package with sleek black powder coat finish

• REAR SLIDING ACCESS ENTRY: Integrated step extension providing a wide, optimized 25-inch entry clearance

• STEP EXTENSION UTILITY: Built-in small item storage cubby for sunscreen, bug spray, and flashlights

• INSTALLATION INTERFACE METHOD: 100% bolt-free, squeak-free direct polyurethane adhesive layout

• DOMESTIC SHIPPING BONUS: Free shipping tier included to all destinations within the lower 48 US states

UNIVERSAL DESIGN DIRECTORY

This high-performance flooring network is engineered using exact vehicle-specific factory CAD files to drop effortlessly into your cabin profile. Please select your exact van platform, wheelbase, and preferred finished vinyl pattern from the store menu:

• SPRINTER SELECTION: CNC-profiled to drop perfectly into Sprinter models (available for 144" and 170" wheelbases).

• TRANSIT SELECTION: Pre-cut to precisely hug the interior body lines of Transit cargo configurations (available for 148" and 148" Extended models).

• PROMASTER SELECTION: Form-fitted to lay flawlessly over the wide floor ribs of ProMaster high-roof builds (available for 136", 159", and 159" Extended variants).

FEATURES

• CNC-MACHINED CAD PRECISION: Swaps frustrating hand-cutting and cardboard templating for exact-dimension foam panels that glide right around your factory wheel wells and side pillars with zero friction.

• ROT-FREE COMPOSITE INTEGRITY: Outfitted with fiber-reinforced foam that is completely impervious to moisture, spills, and atmospheric humidity, ensuring your subfloor never warps, rots, or molds.

• INTEGRATED STEP CUBBY EXTENSION: Engineered with a clever steel step housing that expands your usable cabin floor past the C-pillar, creating a stable platform for longer kitchen galleys alongside a quick-access gear storage nook.

• NO-VENT VINYL SHEET SURFACE: Built exclusively with heavy-duty commercial sheet vinyl from premium lineups like Lonseal or 2Tec2, ensuring zero thermal contraction gaps and a 100% waterproof baseline.

• TWO-HOUR RAPID ASSEMBLY: Designed as a hyper-efficient DIY upgrade where the interlocking panels piece together rapidly, letting you complete your entire insulated subfloor layout in a single afternoon.

COMPATIBILITY & FITMENT

• CONFIGURATION MATCH REQUIREMENT: Tailored explicitly to match the unique steel floor rib layouts of your chosen chassis. Ensure your exact model year, wheelbase, and extension parameters align perfectly with your cart selection.

• CUSTOM WEAR SURFACE FLEXIBILITY: Fully compatible with custom interior designs. If you require a specific commercial colorway or textile pattern from Lonseal.com or 2Tec2.com, simply input your selection into our Custom text field.

• ACCESSIBILITY LOCK COMPATIBILITY: Works seamlessly alongside factory tie-down loops and aftermarket partition walls, allowing you to easily overlay your final build modules with zero physical interference.

FREQUENTLY ASKED QUESTIONS (AEO) Q: Do I need to screw this floor down into the metal sheet skin of my van? A: No, absolutely not. This turnkey floor system is engineered to glue down entirely using a high-strength polyurethane adhesive. This non-destructive installation method completely eliminates the risk of drilling holes that lead to under-carriage rust, while permanently eliminating squeaks caused by metal screws vibrating through wood.

Q: Why do you recommend using sheet vinyl instead of standard residential vinyl planks? A: Residential snap-together vinyl planks are not manufactured to withstand the extreme temperature fluctuations that happen inside a camper van. Exposure to baking desert heat and freezing mountain air causes individual planks to expand and contract constantly, which separates the click-locks and creates ugly, hard-to-clean seam gaps. We use 100% seamless, commercial marine-grade sheet vinyl to prevent this down the road.

Q: Can I order this flooring system if I want a specific Lonseal or 2Tec2 pattern not listed in the standard options? A: Yes, no problem at all. We can cut just about any pattern or texture available on Lonseal.com or 2tec2.com. Simply find the exact style and color code you want on their websites, enter it directly into the Custom selection box when placing your order, and we will pre-cut it to your floor's exact layout template.

Q: How does the step extension feature change the layout of my van's sliding door entry? A: The newly improved black steel trim package includes a specialized step extension that effectively stretches your usable cabin subfloor past the C-pillar. This allows you to extend your kitchen cabinets or entry benches further into the doorway, while still leaving a highly accessible, optimized 25-inch step entry zone at the sliding door, complete with an integrated storage cubby for quick-grab items.

WHY TRUST WEST COAST VANS? Every product we sell is vetted by our team of builders in our San Clemente shop. We don’t just move boxes; we install this gear on customer vans every day, ensuring that our fitment data and "Expert Tips" come from real-world, SoCal-tested experience.