Inspired by Mike Chell's 2018 thread, and coveting the more than 6 cubic feet of storage space Ford hid under the cargo deck, I took the plunge and removed the deck hiding the second row foot well. I'm looking for ideas on how best to finish off the hole. One thought is to build a new deck that is level with the existing deck and add hatches to get to the under storage. I may end up doing that, but it seems I'll want insulation and a neater bottom than just the bare metal, so a floor seems imperative.
An aside: I had read that the Government changed their import tariffs that motivated Ford to import Connects as passenger vans, and that Ford no longer did this. Below is a photo of the front matting that extends to the second row. This mat is under the deck. You can clearly see there are threaded holes with the paint gone, and scratch marks near the locator holes, so it is obvious this 2021 van, purchased new as a cargo van, once had a second row of seats. Does Ford just throw those second row seats away? Or perhaps they are shipped back to Europe to put into the next shipment of "cargo" vans.
Back to the topic: Now that I've got that hole, I'm trying to figure out what to do next. My current thinking is to just install a floor on top of the lateral beam (the side-to-center pieces with multiple sets of three holes). I'm going to cut the mat further forward, to where the threaded, bolt hole is at the forward edge of the door opening, so I can secure a wood beam to those threaded bolt holes. I can bolt my new floors to the top of the lateral beam using the bolt holes for the second-row seat mounts. I think I need to add some blocks at the rear wall, either just on the floor or glued to the wall. I think the floor and wall are exterior under surfaces, so don't want to drill.
I'll bend the current floor mat, which has about an inch of foam under it, down to cover the front-facing wall. My thought it that will help with noise and thermal insulation. Seems like glue will be the way to attach the matting. Hope it doesn't dissolve the foam under the matt.
Speaking of insulation, I'm going to want some insulation under the new floor boards. Was considering using spray foam but I understand that stuff needs air to cure and it doesn't seem like it will get much air down in that pan with a wood floor over it. I guess I can just stuff the cavity with fiberglass, building insulation. Would you consider using sawdust? Custom cut the jig-saw style foam flooring? Any recommendations?