This emoji pretty much sums up how I feel about cutting holes in the van: 😬 I’m excited about the outcome, but I am extremely nervous about the actual process of removing sheet metal from the van and hoping that whatever we cut the hole for fits.
Today we cut TWO massive holes in the van. The first for the MaxxAir fan and the second for one of two windows. I’m going to detail the fan installation in this blog post, and cover the window installation in tomorrow’s blog post since we’ll be installing the second window then.
12 Steps to Install a MaxxAir Fan
We bought the MaxxAir fan (5100K Deluxe) from Amazon Warehouse and based on the description we were pretty sure it was discounted to $231 because it was in a damaged box, not because it was new. We received it in the mail on Thursday, opened it up, and found out that it was brand new and the damaged box didn’t impact the fan at all.
Here are the # steps to install a MaxxAir fan in the roof of your Sprinter van conversion.
Tools & Materials Needed
- Jigsaw
- Jigsaw metal cutting blades
- Pencil
- Silicone caulk
- Drill
- Drill bits the size of jigsaw blade and screws
- Metal File
- Spray paint
- Cardboard box
- Shop vac
Step 1: Read Installation Instructions
I’m kind of a stickler for reading the instructions for things, but ESPECIALLY so when it involves chopping a big hole in my van’s roof! We both read all of the installation instructions (they weren’t that long, maybe 2-3 small pages) for the fan before we got started. That way when we were doing the install, we could check with each other that we were doing it right. We also brought the tiny instruction booklet up to the roof while we did it for quick-reference.
Step 2: Clean Area
Yesterday, I washed the roof (and the rest of the van) in preparation for the Maxxair Fan Installation. I did this without actually getting up on the roof, so when we got up there today, we could see that it was still too dirty in the area we were going to install the fan. So we grabbed the ArmorAll glass cleaner (aka expensive Windex) and wiped the area clean again.
We also thought we might need to scrape off the soundproofing tiles. When we tried, they started breaking off in tiny pieces. So, we just left them and cut right through them.
I want to make a note here that when you’re walking on your roof, you want to be gentle, and try to step on the bump-ups, which are a little more supported. Also, the areas towards the edges are more supported than the center of the van roof. This way you won’t dent your roof. When we cut the hole for the fan we found out that the metal was a little thicker than we expected, so we didn’t worry as much about denting the roof, but we still were careful when we walked and made sure not to drop any tools too.
Step 3: Trace the Insert
Lay the insert down where you plan to install the fan and trace it with a pencil or pen. Make sure you’re tracing the correct part!
Step 4: Tape Around the Outline
Put painter’s tape down around the outline you just traced. This will keep the jigsaw from scratching your paint as it drags along the surface. Be sure to leave a small gap between the tape and the line so you can still see the line you traced! And check that the tape is as wide as the area that the jigsaw will contact.
Step 5: Drill a Hole
Drill a hole in one of the corners that is a little bigger than your jigsaw blade. This is where you’ll start your cut with the jigsaw.
Step 6: Cut the Hole!
Stick the jigsaw into the hole you just drilled, and follow the outline around until there’s a giant hole in your roof! When you’re 3/4 of the way around, I’d recommend taping one side so that the piece of metal swings down instead of just dropping through. This also helps prevent wiggling and vibration of the sheet metal.
Once the hole is cut, wipe down the edges with a rag and try to fit the insert in. You’ll probably have to do a few more small cuts to get it the right size because the jigsaw doesn’t cut perfectly straight.
Step 7: File & paint the edges
Use a metal file to clean the edges. Be sure to brush off (using a dustpan brush) or wipe off (using a rag) the small metal shavings around the hole. Then spray paint the outside and inside of the hole to prevent rust. We pressed a cardboard box up against the hole on the inside (when spraying the outside) and outside (when spraying the inside) to prevent over-spray.
Step 8: Pre-drill screw holes
Replace the insert and trace with a pencil inside the holes where the screws will go. Then, use a drill to pre-drill the screw holes. Make sure the drill bit is the right size for the screws that come with the fan.
Step 9: Caulk
Add LOTS of silicone caulk (we chose clear so it would be invisible) to the bottom of the insert, where it will sit flush to the roof of the van. Honestly, more is better. You want this puppy to be watertight! Then flip the insert over and carefully put it in place. Make sure that the metal tabs face the sides of the van, as indicated in the instructions. Since the hole is a 14″ by 14″ square, you don’t have to worry about cutting the hole wrong but make sure you don’t place the insert incorrectly. Some caulk will squish out through the screw holes and around the edges – that’s OK. You can remove any extra later after it dries. In fact, we even applied extra silicone caulk to the screw holes to make sure those were watertight as well.
Step 10: Screw Insert Down
As I mentioned, we applied silicone caulk to the screw holes too, then hand tightened the screws with a screwdriver. We didn’t use a drill so that we could control how tight the screws were, and we wouldn’t damage the plastic insert.
Step 11: Place The Fan
Put the fan in the insert! There are only 4 more screws that you have to put in. Before you screw the fan in, make sure you pull the wires through so that you can do the wiring on the inside. Also, make sure that the vent is open when you install (per the instructions). Then screw it down.
Step 12: Clean Up
Cutting a hole through sheet metal means a lot of tiny metal shavings everywhere. You’ll want to clean this up extra good to make sure that they don’t create surfaces for rust to start. If you have a bulkhead door, I’d recommend closing it so you’re not getting metal shavings on your seats. Then, shop vacuum everything up when you’re done.
Tip: Try to catch the metal shavings in a bucket to prevent them from getting everywhere. This will make cleanup easier.
The Verdict
I was so nervous, but there was really nothing to be worried about. The fan fits great, it seems super watertight, and it looks really good. Overall, the install only took us about two hours, but you could do it a lot faster than that if you’re a little less worried than me 😉
I’m really happy we went with white, because it blends in nicely with the fan when it is up, and when it is down you can hardly see it at all from the ground! Additionally, the fact that it is a manual (vs remote) model doesn’t seem to be an issue at all.
Next Up: Windows
We actually stayed up until 11:00 PM installing one of our windows today into the driver’s side of the van. Since we’ll be installing the second window tomorrow, I’ll give you the low down of the entire process in tomorrow’s blog post.
9/11/2020
Build Day #13
Hours Worked: 20
- Becky – 8
- Austin – 12
- Total Project Hours: 152
Money Spent: $0
- Total Project Spending: $18,356
Tasks Complete: 2
- Install MaxxAir fan
- Install 1 window (driver’s side)
Questions Googled: 0
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