Fan-Tastic!

After my buddy Jim helped me install the window, I decide to tackle installation of the roof ventilation fan by myself.  I figured, hey, I can do this!  And, actually, it wasn't too bad, but I did discover (not surprisingly) that my metal-working skills are nowhere as good as Jim's.  Unwittingly, I made one cut with the angle grinder about 1 inch too long.  Fortunately, this would be underneath the mounting flange and easily sealed up with butyl tape & sealant.  Phew, that was close!

The fan was one of the few, if not the only item I purchased that was top-of-the-line.  The Maxxfan is widely regarded as the "Cadillac" of RV roof ventilation fans, and I purchased their deluxe model, which includes 10 speeds both in & out and a remote control.  Originally I wasn't going to get the model with the remote, but where the fan is located (above the bed and near the rear doors), it would be cumbersome to operate the controls manually.  So, I went all out!  

I decided to locate the fan above the bed for a couple reasons: one, it would create some cross-flow ventilation in the van with the window was open, and two, it would enable cooler air to be brought in at night (I'm one of those people who like to have air moving while sleeping).

The Maxxfan Deluxe, fresh out of the box

 

The first step of installation process was to cut a square opening in the metal roof.  Like the window installation, this was a little scary, but I was up for the challenge.  I started with a jigsaw, but towards the end the metal got too wobbly, and I had to switch to the angle grinder.  Using the grinder for the entire cut probably would have been best, but I found that it was difficult to control the grinder since I was kneeling on the roof and working only from one direction.

After cleaning up and priming the edges, the next step was to install the roof flange in place using butyl tape and screws.  I built a wood frame on the ceiling and around the fan opening to provide some extra strength and to have something for the screws to grip into besides just the roof metal (which is pretty darn thin).  Then drop the fan into the roof flange, secure with screws, and seal everything up to prevent water from getting into the van (I used both butyl sealant and a rubberized sealant spray).  Overall, I think it was a success!  (It rained pretty hard the next day, and there was no evidence of water leakage...yay!).

The cutting line

The opening -- notice the "oops" at the upper right-hand corner!

Installed fan -- front view (looking towards rear of van)

Installed fan -- side view

Installed fan -- inside view.  Note the wood frame

 

My biggest challenge during the whole process was getting onto and off the van roof.  Initially I had planned to access the roof via the rear ladder.  But, when I tried to do this, I realized there would be no graceful -- and probably safe -- way of getting off the ladder onto the roof, and vice versa (which begs the question of the utility of this ladder for me going forward...but hey, it's there!).  So, I got an extension ladder and set it up on the side of the van.  Getting on the roof the first time was no issue, but I realized that getting down might be a bit more hazardous.  I wasn't afraid of being on the van roof (slanted roofs are another story) or climbing the ladder itself, but I was a little nervous about the potential for the ladder to shift when stepping onto it to get off.  Fortunately, our neighbors across the street were having a garage sale, so I yelled over to Evan to help hold the ladder for me.  He also helped hand me some things I forgot to take up with me (like my drill when I forgot I needed to pre-drill the holes for the flange or an extra battery when the battery on my jigsaw died).  Thanks Evan!

The only remaining roof project would be installing the solar panels, but hopefully I won't even need to get onto the roof to do this.

Moving forward!!!