HUH, I thought I wrote about what I ended up doing, but it appears that message ran away.. So this is what I ended up doing:
I have a wall separator between the front and the living (cargo) area, one of those cargo van dividers, that has a door. The door opens into the living area, so I had to make sure my flooring solution allowed for room to open/close the door, which was exactly @ 1/2". I ended up just putting down 1/2" plywood, cutting it to fit around the wheels, etc. The plywood is not bolted down anywhere, except in 2 spots, but it has a very snug fit, so it's never moved anywhere.
Since my cargo area is 12' long, I did have to join 2 pieces together. I cut little strips of plywood that would fit inside the V channels that the metal floor had, and used those under the floor to then screw the plywood together. (not sure if that makes sense, but you put a piece under the plywood and then screw down from the top. to keep it all flush, I made the pieces under the plywood floor fit inside the V channels that the original metal cargo van floor has).
Overall took a full afternoon with a helper (had to UNLOAD the entire van to get to the floor AND reload it all up). By myself, I could have done it in a full day, with lots of breaks and thinking and measuring 400 times per cut to make sure I got everything right! Total cost was about $100(?).
I've had plywood down for 6+ months now (did it last winter). I'm very happy with my plywood floor. It's evened it out, and made it nicer. It no longer feels cold to my bare feet. It's not fancy plywood or anything, and I didn't sand it down or treat it in any way (tho I really probably should have).
Total Build time: 1/2 day with helper, full day alone.
Total Cost: Around $100 for the 2 4x8 sheets of plywood, screws, etc.
Difficulty: Not that difficult, if you can measure, cut and carry 4x8 sheet plywood.
Left Overs: screws, and about 1/2 sheet of plywood
With Love,
Tara