Removing 3rd row flooring, what to fill recesses with?

[iamdub]

Wondering what I should use to flatten the floor. Should I fill the recesses with more jute padding or is there something better?

A cover made of cabinet-grade 3/8" birch would be smooth, lightweight and plenty strong. Use 3M spray adhesive to cover the top with thin automotive-grade carpet (like for speaker boxes). It'd be a stronger version of the pressboard trunk floor covers used in passenger cars used to cover the spare tire well. Also, like in the cars, you can cut the birch laterally or longitudinally and the carpet would act like a hinge so you can fold it for easier installation and removal and more compact storage if that's a factor.

 

[m1949]

Spray foam insulation should work. Get the type that hardens and has less expansion. You can cut off any excess flush to the floor.

 

[EddieC]

We took all the back seats out and built a wood platform.
Now we have a sedan delivery. And the space is big enough for a nice place to sleep in the National Forest campground. Pretty bear proof to boot.

 

[mikez71]

Spray foam insulation should work. Get the type that hardens and has less expansion. You can cut off any excess flush to the floor.

That stuff can be pretty hard.. Was thinking about making some metal plates, but probably not worth all that effort..
well it might be worth it for the big center crater...

Going to tackle it soon, after I get some wiring done..

 

[Mean_Green]

Maybe we need pictures of the area in question.

 

[mikez71]

Maybe we need pictures of the area in question.

Not as big as i thought..

need to take out the bolts. maybe some silicone in the bolt holes.. dents are about 3/4" deep, rising bumps about 1/2" high. expanding foam is sounding pretty good.. maybe cut some rubber pieces to fill it..

 

[Mean_Green]

Just get some more of that carpet padding. Cut pieces as needed to fit the holes. Maybe two or three layers. Cut one square and three rectangles to fill the deep holes, then another larger set, on top of those. Then one more larger to fill in and to level to the surface layer. I'd still go with a piece of plywood on top of the padding.

You mention rubber. Consider those anti-fatigue mats from Harbor Freight (and other places). They cut quite easily and are dense enough to prevent compaction over time.

I'd leave the bolts too. The padding will settle around them and you won't have a leak source from below.

That canned foam degrades and decays to crumbles and powder over time.

 

[iamdub]

Not as big as i thought.. View attachment 398140

need to take out the bolts. maybe some silicone in the bolt holes.. dents are about 3/4" deep, rising bumps about 1/2" high. expanding foam is sounding pretty good.. maybe cut some rubber pieces to fill it..

Expanding foam doesn't squish very well. It'll crumble if you happen to kneel or put weight on it and eventually turn into a yellow, crumbly mess that'll disperse all under the carpet.

I like the rubber idea. Cut some pieces to fit down in the lowest parts and larger pieces to cap that and cover the rest to bring it up the height of the bumps. Sandwich them with glue between each layer. For $10 at Harbor Freight, you can get plenty of material: https://www.harborfreight.com/4-pie...IFX9GyyDMnOOH_jzKjLKnuH5ZxqN-lehoCvjAQAvD_BwE

You can replace the bolts with set screws. Use a little thread sealer, maybe even a little BLUE thread locker to keep them in place.


*EDIT* Just saw that @Mean_Green wrote almost the exact same thing. Great minds...

 

[89Suburban]

Maybe try a small test area with this stuff.

https://www.euclidchemical.com/fileshare/ProductFiles/TDS/Euco_QWIKjoint_200.pdf

Or this.

https://www.euclidchemical.com/fileshare/ProductFiles/TDS/Dural_Fast_Set_Gel.pdf

 

[mikez71]

Heck yea, good info. Don't need no crumbly foam. Will find some rubber and get to it! Thanks for all the help collective hive mind!

As for pouring some polyurethane, it would be stronger im sure, but that stuff usually stinks for a few days and im afraid ill make a mess somehow.. would lean that way more if i didnt think rubber will do the trick adequately..

For the bolts..Not sure if they sell set screws that big or I can cut a threaded rod into pieces maybe.. but then maybe ill just grind the bolts down to shallow domes..Heck if I can find plastic or rubber plugs, I might silicone them in place..and on the bottom..usually need a few plans, for when something doesnt go as planned!

Also got this today..

I thought it was a top mat when i ordered it, guess ill have 2 layers of vinyl! Ill put the oem under the tan aftermarket..