Home, Vanlife Build

Vanlife Build: Cutting large holes in the van. Totally normal.

Ask any vanlifer what the hardest part of their build was, and they’ll tell you it was putting in the roof fan. It’s not all that complex or physically demanding, but the mental anguish that comes with CUTTING A LARGE HOLE IN A PERFECTLY GOOD VAN is palpable. But it’s a rite of passage that all of us go through. Once it’s done, you realize it’s not that big of a deal. But I was still sweating it.

Why a roof fan? They are nearly mandatory if you’re going to be spending any time sleeping inside. They make a huge difference in keeping the interior temperature comfortable, and whisk away cooking and “other” odors. Plus, just breathing as you sleep causes condensation, which will eventually lead to mold.

After doing a lot of research, we went for the top of the line Maxxfan Deluxe, sourced from Amazon for $265. This one is unique in that it can be fully open in a downpour. It has 10 speeds, blows in or out, raises electrically, and comes with a remote control. It had great reviews across the board.

So, on to the install! We decided to put it nearly in the center of the van. This kept it out in front of the roof box, while still leaving plenty of room in the front of the roof for solar panels. Plus, it will be close to where we are putting the cooking stove.

I started by measuring it out and using a carpenters square to get the precise line. Some people say to use the trim ring, but I found that I couldn’t get a Sharpie in there. I then used masking tape to give myself a good sight line.

Basic layout, and some of the tools I used

And now we’re at the point of no return. I took a deep breath, and drilled all four corners to create space to put the jigsaw blade.

Drilling the corners

Next, I simply grabbed my jig saw (ensuring that I had a sharp blade), and connected the dots. Some people prefer to use electric metal shears because it creates less metal shavings, and I would definetely recommend that if you have access to one. DO NOT use a sawzall or grinder! Pro tip: Make sure you lay down something to collect all these shavings, AND to prevent the cut piece from dropping and damaging your pretty new floor. Whoops!

I may look calm, but…

Once it was done, I sat back and thought, “In essence, I’ve just totalled my vehicle”. No matter, ONWARD!

Resale value enhancer

I hit the cut edge with some rust inhibitor and let that dry. Afterwards, I cleaned the surface and vacuumed up all the shavings.

Here’s where I cut a corner that I might have to come back and redo. Every blog I read said that the best adhesive/sealant was from this brand called Dicor. But it was Sunday during the pandemic, and the only thing open was Walmart, so I had to settle for a similar product. I layed down a bead on the roof where the fan frame was going to rest, then set it in. The kit came with some self tapping screws to really secure it to the metal. I put a bit of sealant on the head of each screw as well. The Walmart sealant wasn’t all that easy to work with, being a little too thick to make it pretty. Looks like it’ll keep out water though.

The next best thing in a pinch

Then, I simply attached the fan to the frame, ensuring that the wiring didn’t get pinched.

I came back inside, and temporarily wired it to the dome light circuit. It works perfect! The remote has a thermostat that allows you to set a temp, and the fan will do the rest. (Within reason of course, it’s not an AC unit.) I will eventually be running the wiring into the fuse box I’ll be creating for the electrical system.

And there you have it!

Post script: I felt pretty awesome about this afterward. This was a big step, and something I had never done before. It boosted my confidence enough to do something stupid, like the following…

We knew we wanted to install some windows on the drivers side to bring some light in where the dinette would be. So I ordered what I thought would be the correct RV windows. What I failed to account for was that the sides of our van have some curvature. And the windows had none:

Seems like a water entry point

So, there will be a big gaping hole in the side of the van till the correct window gets here. Because I’m a big dummy.

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