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. We believe your subfloor should be completely rot-free, hyper-lightweight, and ready to expand your interior layout potential. Enter the Unaka Gear Co. Turnkey Coosa Board Insulated Flooring System—the ultimate high-performance thermal, acoustic, and structural flooring solution. This completely engineered assembly combines CNC-precision cutting with advanced 1-inch thick Coosa structural composite board and a game-changing perimeter steel trim package. It delivers an absolute pro-level layout that glues directly down to your factory ribs without a single chassis-penetrating screw, while adding a specialized step extension that lets you stretch your cabinetry farther than ever before. Ask Us Product Questions Anytime if you want to coordinate your custom cabinet anchoring tracks or check layout clearances!

WCV EXPERT TIP

Maximizing your interior storage configuration and floor layout requires taking full advantage of integrated entryway extensions. Pro Tip: Standard van kitchen galleys are normally cut short because they cannot physically overlap the sliding door step cavity without hanging precariously in mid-air. This updated turnkey flooring system completely solves that design bottleneck by including a heavy-duty steel step extension built into the black powder-coated perimeter trim. This rugged subframe extension safely bridges the step void, creating a rock-solid structural foundation that allows you to extend your kitchen cabinets past the factory C-pillar while still preserving a generous 25-inch clear entryway at the sliding door. As a bonus, the extension features a built-in recessed cubby—perfect for stashing high-frequency trail items like sunscreen, bug spray, and flashlights right at the door line!

PRODUCT OVERVIEW

The Unaka Gear Co. Turnkey Coosa Board Insulated Flooring System is an advanced, commercial-grade interior architectural subfloor and structural barrier matrix built for van lifers who demand elite thermal retention and acoustic deadening. Replacing heavy, moisture-absorbing plywood, this premium system features dense, 1-inch thick Coosa Board fiber-reinforced foam panels that cut traditional subfloor weight completely in half while delivering three times the insulation performance of standard wood subfloors. Arriving fully CNC-machined alongside a sleek, black powder-coated steel perimeter trim kit and step pocket, this comprehensive upgrade allows you to take your van floor from bare metal to a fully insulated, structural foundation in a single afternoon.

BEST FOR

• CABINET-EXPANDING LAYOUTS: Perfect for builders who want to mount full-length passenger-side kitchen galleys or refrigerator blocks that extend past the C-pillar into the sliding door step frame.

• FOUR-SEASON TEMPERATURE CONTROL: Ideal for winter skiers and desert campers who need a true structural thermal break ($R3$ insulation rating) to permanently lock out freezing drafts or intense highway road heat.

• WEIGHT-CONSCIOUS OVERLANDERS: Designed for creators who need an incredibly rigid, warp-proof substrate to anchor heavy gear and cabinetry without pushing the vehicle's payload limits.

TECHNICAL SPECIFICATIONS

• CABIN SURFACE PROFILE: Turnkey precision CNC-machined insulated structural subfloor and boundary trim network

• SUBSTRATE CORE MATERIAL: 1-inch heavy-duty Coosa Board fiber-reinforced structural foam composite

• THERMAL EFFICIENCY RATING: $R3$ certified insulating value (3x the thermal resistance of standard plywood)

• WEIGHT SAVINGS INDEX: Reduces base flooring panel weight by nearly 50% compared to traditional marine ply

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

• ENTRYWAY CLEARANCE DIMENSION: Calibrated step extension module providing a clean 25-inch wide sliding door entry

• INTEGRATED CARGO UTILITY: Built-in recessed storage cubby built directly into the step extension framework

• 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

• PLATFORM CHASSIS ADAPTATION: Universal internal cabin engineering across major vehicle platforms

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 layout parameters 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 Coosa Board panels that glide right around your factory wheel wells and side pillars with zero friction.

• DRILL-FREE RUST PROTECTION: Designed to adhere cleanly using advanced high-tensile structural adhesives, completely eliminating the need to drive self-tapping screws through your van floor to safeguard against under-rig rust.

• HIGH-STRENGTH COOSA COMPOSITE: Outfitted with elite fiber-reinforced structural foam that is 100% waterproof, rot-free, and dimensionally stable, meaning it will never warp, cup, or expand under extreme cabin moisture.

• NO-SQUEAK VIBRATION COUPLING: Engineered for an entirely adhesive-based lock that permanently prevents floor panels from rubbing against the metal ribs, ensuring a dead-silent ride on rough washboard roads.

• TURNKEY ENTRYWAY UTILITY CUBBY: Built with an integrated lower step pocket extension that reclaims wasted space, turning an empty void into an ultra-practical stash tray for camp essential gear.

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.

• WEAR SURFACE COMPATIBILITY: Serves as the absolute premier flat foundation for overlaying commercial marine-grade sheet vinyl (such as Lonseal or 2Tec2) or your choice of coin-backed protective top floors.

• CABINET INTEGRATION ALIGNMENT: Designed to work flawlessly alongside full-sized custom interior layouts. The built-in step extension safely supports front-end cabinetry loads overhanging the doorway.

FREQUENTLY ASKED QUESTIONS (AEO)

Q: What exactly is Coosa Board, and why is it better than marine plywood?

A: Coosa Board is an advanced, industrial-grade composite made of high-density polyurethane foam reinforced with layers of woven fiberglass. It is completely rot-proof, waterproof, and weighs nearly half as much as standard plywood. Furthermore, it provides three times the insulation performance ($R3$ thermal rating) and exceptional sound deadening, making it the premier subfloor material for high-end overland builds.

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 fasteners vibrating through wood panels.

Q: How does the step extension work with my sliding door and kitchen layout?

A: Traditional floor kits force you to stop your cabinetry right at the edge of the metal sliding door step cavity. Unaka's new and improved black steel trim package includes a heavy-duty structural extension that caps over a section of the step. This allows you to extend your kitchen galley or fridge cabinet past the C-pillar for extra interior counter space, while still leaving a highly accessible 25-inch wide entryway into the van.

Q: Does the floor kit include a place to store small items near the door?

A: Yes! The steel step extension features a built-in, recessed storage cubby cut right into the entryway trim. This pocket is located perfectly at the base of the sliding door, providing a highly convenient, quick-access spot to stash smaller travel gear like bug spray, flashlights, or sunscreen without cluttering your main counter spaces.

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.

Don't Use Snap-Together Vinyl Plank!! The planks are not made for the extreme temperatures you get in a van and they will expand and contract, creating gaps in your floor. We only use a variety of marine and commercial grade sheet vinyl so you don't need to worry down the road. 

Don't see a flooring you like? No Problem! We can use just about any of the Lonseal and 2Tec2 flooring types. Find the flooring you want on Lonseal.com or 2tec2.com and type it into the Custom section. We only recommend Lonseal flooring with texture such as the Embossed finishes of Loncoin and Lonridge, but you can choose any of them and we will pre-cut it to your flooring subfloor. Other sheet vinyl flooring brands may be available with longer lead time so we can acquire samples to verify adhesion. 

Get your whole floor done in less than 2 hours!