Maxx Air Fan Install
Installing our Maxx Air Fan
Would you trust Chris with cutting holes in your van?!
Time to cut some holes in our brand new van! Safe to say most van builders really dread taking this step but it really wasn’t that bad. Make sure to triple check your measures before you make any cuts and everything will work out.
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Where to place the fan
We decided to install one Maxx Air Fan near the front of the van for a few reasons. We knew we would be able to circulate the air with the bunk windows in the back that opened up and we also wanted the fan to be above the stove area (which we placed near the sliding door). Placing the fan towards the front also made it possible for us to have a deck on the back half of the roof rack.
Start with a template
First we created a template of the inside section of the fan (approx 14” by 14”) then taped it to the ceiling on the inside of the van.
To mark the center on the roof we drilled pilot holes in the center of the template and on all 4 corners through the van ceiling. These will be used as reference points when we move up onto the roof as it’ll be easier to use the jigsaw on the roof.
We then took the template from the inside and placed it on the roof, matching the center hole in the ceiling with the center hole on the template (to help keep the template in place put a nail through both center holes). Once we had the template all lined up we used a sharpie and traced around its edges and then placed tape around the outline.
Cut the hole (fingers crossed)
Before moving onto the next step we used plastic sheets and created a net under where we were going to cut so that any metal shards would be caught and wouldn’t scratch the floor (possibility of rust forming).
Using a drill and a drill bit create 4 bigger holes on each corner of the tape outline (make sure the drill bit is meant metal and that it’s wide enough for the jigsaw blade to fit comfortably into the hole). Take the Jigsaw with a metal cutting Jigsaw blade and place the blade down into the holes you’ve just drilled out. Now that you have the holes in each corner all you have to do is make straight lines connecting each hole in the corners.
We did it, our first cut out in the van is done! To protect the freshly cut metal from rust we filed down any sharp edges and applied Paint & Primer to prevent the possibility of rust forming.
Tip - Before you finish the last cut you should add some strong tape across the roof and over the piece of metal that is going to get cut out, so that it doesn't fall and damage something below while you finish cutting the last edge.
Install the Flange
Next we laid down butyl tape approximately an inch away from the perimeter of the cut out which will act as a sealant under the Maxx Air Fan. We doubled up the butyl tape on the sections of the roof that are lower so that once the Maxx air fan flange was placed onto it would lay level.
Make sure you pay attention to where the metal clips are because this will determine the orientation of the fan and how it opens.
We then placed the flange of the fan on top of the butyl tape and screwed it down into the roof of the van. It’s a good idea to alternate sides when screwing down the screws and don’t go all the way tight until all screws are roughly 90 percent drilled down. This will help the flange go down evenly.
Attach the Fan
Then drop down the fan unit into the flange and make sure that it can open and close all the way before screwing the fan onto the flange. Make sure the wire for the fan is accessible and not tucked up away into the flange before you attach the fan unit. Not necessary but at this point we trimmed off the excess butyl tape that was sticky out past the flange.
Weather Sealing
Once the base was connected to the fan unit we used a powered caulking gun and applied self-leveling lap sealant on top of each screw on the flange and around the edge of the butyl tape/flange. The self-leveling sealant will quickly level out so don’t go crazy with the amount.
The fan is fully installed!
Allow 24 - 48 hours to fully dry and then spray some water consistently over the lap sealant to make sure no leaks occur.
Now we’re ready to cut out holes for the windows!
Approximate Cost
$600 CAD
(Not including tools)
