The Floor

The floor is made of 2" foam with 1/2" plywood laminated on top. GreatStuff (tm) foam was used as the glue. The 2" foam fits down in the frame.

To do the laminating, I need to have everything wrapped in plastic, so I pulled the foam back out, laid plastic over the frame then dropped the foam back in. The plastic will keep the floor from sticking to the frame and will allow me to vacuum pack the whole thing.

Next squirt the GreatStuff on the foam (sorry, no pictures), then the plywood goes down. The perforated vacuum hose goes next, then the plastic is folded over and the seam is taped. Once the vacuum is switched on and the air gets sucked out, air pressure squeezes everything together.

I let the vacuum run for about 6 hours. The can said the foam took 8 hours to cure, but it was bed time and I didn't want the vacuum to run all night. The next day, I stood the frame up, popped the floor out of the frame, removed the plastic, put the floor back in, then drilled the bolt holes through the foam and plywood. I used the pre-drilled holes in the brackets to align the holes.

I now have a rigid, insulated floor. Time to build the walls.

If I had this step to do over, I would have placed a scrap of plywood over the plywood joints and temporarily screwed them together. This would have made it easier to get everything lined up and reduced the chance of things slipping while getting the vacuum pack going. The plywood shifted a little, so I had to trim things once it was all set up.