VW T6.1 Kombi floor conversion: brackets to vinyl

The Problem

The owner needed to remove the rear kombi seat brackets from a VW T6.1 floor before fitting insulation, a plywood subfloor, and Altro vinyl on top. The bracket removal proved impossible without a ramp, and there was uncertainty about which insulation products would sit correctly between the floor battens without causing high spots.

Solution

1. Take the van to a garage with a ramp to have the OEM rear seat brackets professionally removed — the two brackets above the exhaust heat shield are not accessible from above without one.

2. Sand back any surface rust around the exposed screw holes and treat with a dedicated rust converter such as Kurust or Bilt Hamber Hydrate 80, then paint with Hammerite.

3. Apply a blob of Sikaflex into each small hole before inserting a rivet to create a secure, waterproof fill.

4. Cut patches from aluminium sheet and bond them over the larger kombi bracket holes using a generous application of Sikaflex.

5. Fill the tie-down bolt holes using bolt hole plugs sized to match the thread (search eBay/Amazon for "M8 threaded blanking plug" or the relevant thread size — measure your tie-down bolt diameter before ordering, and verify the exact size against your fittings). Secure them with a medium-strength threadlocker such as Loctite 243, which still allows removal later if needed.

6. Fit Dodo Mat Deadn Duo (4.5mm standard) or Deadn Duo Pro (7mm) between the 9mm floor battens — one roll of Deadn Duo Pro covers an entire SWB floor.

   • Do not use 6mm Super Liner between battens as it does not compress enough and will create high spots under the plywood.

7. Lay a single-piece 12mm plywood subfloor cut to the van dimensions and secure it with Sikaflex adhesive and/or screws.

   • The weight of the ply combined with the adhesive will compress and level any minor undulations in the insulation layer.

8. Bond the Altro vinyl on top of the plywood using an adhesive recommended by Altro, such as Bostik F Ball F46 or Instabond, ensuring enough adhesive is used throughout to prevent lifting (confirm the correct adhesive grade for your specific Altro product before buying).

   • If a gap exists at the rear threshold, cut the Altro slightly longer to bridge it and pack underneath any unsupported sections to prevent sagging over time.