Installing the Fan

We recommend completing these prerequisites before continuing your journey through the steps:

This might go without saying, but decide what the "ideal" placement is inside your van
Structural audit – make sure you won't be cutting into any cross ribs
Roof layout!! If you're planning to do 3 or more solar panels, you will want to know the dimensions of them as things can get pretty tight pretty quickly; although it may feel like the decision on solar panels can wait, you'll want to make sure their layout will align and fit around the fan placement.
Deep breathing. Why is it that the first step in builds is cutting a giant, permanent hole? Rest assured – it's not as scary as it seems and if you mess up there are ways to fix.

Safety Tips:

Careful when on the roof of your vehicle as most vehicle roofs are pretty flimsy
The parts of the van that get cut can get extremely sharp so you'll want to wear gloves whenever you can and be careful when handling any part of the van that has been cut

01

Preparing to cut the hole in your van's ceiling/roof

Start by creating a 14" x 14" square where you want your fan to be. Though not required, this is done easiest with a template of some sort (e.g., that cardboard box lying around). To create the square we utilized blue painter's tape and a black marker. Please note that marking can be done via the roof on the outside of the van, or the ceiling from inside the van. Whichever you think will be easier to cut a straight line is where we recommend you creating the square at. We recommend cutting from the roof for two reasons: arm fatigue and so you're not standing under the shards coming down :).

02

(Optional) Reducing metal shavings during your install

If you're cutting from the roof of the van, consider taping a trash bag around the four corners from below in order to catch the majority of the metal shavings, residue, and shards that will drop during cutting. Some of it will inevitably get into your van, but the more it can be avoided the better and easier it will be for you in the long run.

03

(Optional) Test drill and practice cutting

Drill two test holes near the center of the square you created and practice cutting a straight line so you get a feel for cutting the metal with the tool you're using.

04

Drill starter holes in the corners

Drill pilot/starter holes in each of the four corners of where your fan will go.

05

Cut the hole in the roof

Cut a straight line from one corner to the next. Please note that the more you cut, the flimsier the metal will get which will make the cuts a little harder to execute to stay precise. Just be ready for this and stay focused!

06

File down edges

Clean up the edges of the cutout you just made with a metal filer. Be careful while doing this and wear gloves, those metal points are sharp!

07

Rust prevention

Wipe down any residue or shards and paint over the edges with protective paint (likely, Rust-Oleum) to help prevent rust and cracking and let dry fully (~2 hours).

01

Pre-drilling holes for the fan's flange

Place the fan's flange around the cutout. Move it around until you think it fits best and then take a drill with the proper sized bit to drill pilot holes for each of the flange's mounting holes. Add Rust-Oleum on the new holes you created.

02

Clean and wipe down area

Once dried, clean the edges of where you'll be installing the fan by using cleaning/rubbing alcohol. We cleaned about 6" around the hole to ensure we didn't track and residue or excess oil to where we'd be installing the next steps...

03

Applying butyl tape

Add butyl tape to the outside edge of the cutout. Ensure you layer the butyl tape to avoid air gaps and leaks all the way out past the previously drilled pilot holes.

04

Securing the flange

Fit the fan's flange to the cutout and press down on it to secure it to the butyl tape. The pilot holes won't be visible, but try your best to align it to where you test fit it earlier (you can use a marker or tape to help guide you).

05

Fastening the fan flange to the van roof

Screw in the flange. Tip: In order to bind each side to the van as evenly as possible, do not tighten the screws fully. Once all of them have been lightly screwed in, go back around tightening them in equally.

06

Waterproofing the fan

Seal the edges of the flange by using a generous amount of sealant and let dry (~24 hours). General rule of thumb: don't skimp out on the sealant/waterproofing items. See the materials tab to see what we recommend.

07

Attaching the fan to the flange

Attach the fan unit to the flange using the nuts and bolts provided. Two tips: make sure the fan is facing the right way, and be sure the electrical wires are hanging inside of the van.

08

(Optional) Prepare for rain

Check the weather after you finish your fan install. If it is going to rain, we recommend taping a black plastic trash bah over the top of the work you just completed to help protect the waterproofing you just did. This will reduce the airflow to the sealant, so opening the fan from the inside will help get some air under the plastic bag to help it dry.

Difficulty:

Labor:

4.5 hours

Cost:

$291.01

So... where are we now?