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TAKE THE LEAP

  • Writer's pictureThe Desert Cruisers

Floor Installation in our DIY Box Truck Camper

Updated: Apr 6


Floor Installation Morgan Box Truck Hardwood
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In our 14ft Morgan Box Truck conversion, we worked with our pre-existing hardwood floors. The floors that came with our box are 1-1/8" thick and are fastened to the subframe with countersunk screws.


Morgan Box Truck Hardwood Floor

Sprinter Van Foam Board Floor
Sprinter Van Floor

Given our experience with the Sprinter Van Build, we initially insulated the floor with foam boards, hoping to keep it warm, but didn't notice a significant improvement. The floors always felt chilly. Hence, when it came to our Box Truck Conversion, we decided against adding a subframe floor atop the existing one.



The Process for Floor Installation

With using the floor, we did have put in some extra work to fill the expansion gaps and screw holes in the surface of the floor with epoxy. We did notice that light could shine through some of the cracks, so sealing this up was job number one on the list for our floor installation.


Morgan Box Truck Hardwood Floor

Parts & Tools

Parts & Tools for Hardwood Floor Epoxy

Handy Paint Pail Liners

220 Grit Sand Paper


Preparing the Floors

Vacuum Hardwood Floor DIY Camper

To prepare the floors, you'll want to make sure that everything is extremely clean. Remove any dust or rocks that may be around, vacuum it and wipe everything down with a damp rag. This will help ensure that your epoxy won't have any rocks as it the epoxy hardens and seals.




Creating your Epoxy Mixture

Promise Epoxy Table Top and Hardener

We used ProMarine Suppliers Table Top Epoxy (A), Epoxy Hardener (B), some paint pail liners, and paint sticks. Grab solution (A) and (B) and mix them evenly in a paint pail liner. You'll want an even 1:1 ratio. ProMarine Suppliers has rebranded to Promise Epoxy.


After pouring them into the pail, use a paint stick to evenly mix the solution. We also added in some grey spray paint of Rust-Oleum to give a sparkle shine since we already had it on hand. The Rust-Oleum is of course optional.


Applying the Epoxy to your Expansion Gaps and Screws

Once you have a good amount of solution to start the project, grab your paint and hover it over the screw holes and cracks. This is a tedious job, and you want to try to be as "neat" as possible considering you'll be sanding this down once it hardens. It is self-leveling so it will expand where it's poured onto.



We did this at least two times, with a couple hours in between to make sure it filled the gaps properly. After the first coat, we noticed that sometimes it still needed a bit more considering the floor is 1-1/8" thick and some would seep through. There is no golden number of how many times to do this. Go over as many times as you think you need.


Epoxy Cure Time

According to Promise Epoxy, the curing time should be at least 72 hours, but we had tons of other projects to do on the truck once we got to this point in our build such as our shiplap ceiling boards install, 12V puck lights install, and little projects. Because of this, we let our floor cure for about a month before proceeding.


Staining the Surface

Sanding Hardwood Floor

As soon as the epoxy has had time to cure, sand all the filled epoxy areas, vacuum the mess, and wipe the floor clean with a damp rag.


Once that is done, we picked a Varathane Classic Wood Stain Special Walnut to stain our floor with. We started with a small 8oz just in case we didn't like it. To test it out, we stained the floor where we will have cabinets cover, and we realized that it was the perfect color for us. Just be sure to mix it well before using or else it may appear darker than you expected.


Varathane Classic Wood Stain Special Walnut

Pour the stain into a paint mixture holder. Initially, we bought a cheap brush from Home Depot and realized that it wasn't looking good or spreading evenly. We also weren't going with the grain when applying it either. So we sanded it down, went with the grain and reapplied it with a rag which had a smoother look.


Spreading Varathane Classic Wood Stain Special Walnut

Clear Coating the Floor

Once the stain dried over night, we were happy with the one coat of Special Walnut. To finish it off, we used an Oil-Based Polyurethane Floor Finish to give it a clear, shiny and consistent look. Polyurethane also helps provide a scratch resistant floor.


Varathane Floor Finish Polyurethane Clear

We bought a paint roller & paint tray. Mixed the floor finish, and rolled three to four coats letting them dry in between each time. You can recoat every 12 hours.



We also used 220 grit sand paper in between each coat. We did this because it helped remove bumps and uneven sections of the floor.



Let it dry, then you'll have a nice, even shine and the floor is complete!





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From 2020 to 2023, we embraced life on the road in our DIY sprinter van, The Desert Cruiser. With no prior building experience, we transformed our van into a home, exploring deserts and rainforests, seeking the best campsites, mountain biking, and living our dream. In June 2022, a new dream emerged — building a 2022 Ford F550 into our DIY Earthroamer. With hopes of future family adventures, we found our dream truck in Texas. We believe anything is possible and aim to inspire others to explore life to the fullest!

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