How-To: Fan Installation
First post, what what! This was the first thing I did on my van, so figured it would also be my first writeup, so here we go!
Products Used:
MaxxAir Deluxe
Dicor Butyl Tape - x3 (x1 for just the fan, I used more for the rear Window Install)
Dicor Lap Sealant - x2
Paint - This can be generic, or you may already have some in your garage.
Adapter (Optional) - I did not use this
Tools Required:
Painters Tape
Jigsaw w/ Sheet Metal Blade
Metal File
Paintbrush
Drill Bit
Phillips Head Screwdriver
Garbage Bag
Caulking Gun
Skill Required:
4/10 - You may need a steady hand for cutting.
Time:
3 Hours (Not Including Dry Time)
Installing the fan isn't actually all that physically difficult, it is just nerve-wracking since you're cutting a hole in your roof.
Step 1:
Pick your spot and measure out the size of the hole. The new Sprinters have a designated location up front that fit a fan in nicely, which is where I put mine, but I've seen some people install theirs in the rear. Either works!
If you have the MaxxAir Deluxe the dimensions of the hole are exactly 14"x14", or you can get this adapter from a guy called Hein (remember this name) on his eBay store. After you've measured twice (or a hundred times) mask the edges out with painters tape so you don't scratch the top of the car with the Jig-Saw.
Step 2:
WAIT! Before you grab the Jig-Saw and go to town, make sure you tape a garbage back or some kind of "catcher" underneath the fans to-be location on the inside of the van. You do not want to have all those little metal shavings going everywhere. I used a cardboard box taped to the underside of the ceiling which did a pretty good job.
Once you've got that in place, drill a hole in each corner with a drill bit, or you can use a Uni-Bit if you want to be really cool! It will come in handy later too I swear. Then just go ahead and use the Jig-Saw to cut out your hole! Easy.
Step 3:
Use a file to smooth out the burs and edges, then throw some Rustoleum (or similar) to protect the open sheet metal from rust and let it dry.
Step 4:
Take your Butyl Tape and line the bottom of the fan with a generous amount. I must have skipped taking a picture of this, but I went around the entire thing twice. Once on the inside and once on the outside. Don't worry about excess, you'll scrape it off later.
*NOTE - put your connecting seem on the REAR side, as the seem is the most vulnerable section for water leakage, but the back should be shielded and receive the least amount of water flow.
Step 5:
Place the fan in the hole (with the applied Butyl Tape) and take a small drill bit and make some pilot holes through the screw locations in the fan. Tip - it helps to have a friend hold the fan in place while you drill. Once the pilot holes a drilled go ahead and install the sheet metal screws that come with the fan, I would recommend starting with one screw on one side, then going to the opposite side, and so on. That way you keep even pressure when compressing the fan/butyl tape into place. I also threw a couple 2x3 wooden slats I had lying around on the underside of the roof (inside of the van) so that the screws had some more to grab onto, and so I didn't have sheet metal screws sticking into the cab while I worked on it.
Step 6:
Apply the Sealant over the top of the fan lip/screws. This is the most technical piece of the entire installation, it was harder than I expected to apply it evenly with the caulking gun and I did a pretty sh*t job at keeping it clean looking, but who's ever really going to see the top of the car?
Step 7:
Let the Sealant dry! I put the van in the sun and let it dry for about 24 hours. You want to make sure you don't ruin the sealant when installing the fan.
Step 8:
You're basically done! Once the sealant is dry, just drop the fan into the hole and install the four screws that it takes to keep the fan hooked into the frame.
And that's all she wrote! Except when it comes time to install the trim piece (after the inside roof is installed), but I haven't gotten there yet.
Step 1: Location measured, masked, holes drilled.
Step 2 and 3: Hole cut, filed and painted w/ box to catch shavings. .
Step 4 & 5: Butyl Tape applied under trim, pilot holes drilled and sheet metal screws installed.
Step 5.2: From the underside, wooden slats placed for sheet metal screws to drill into.
Step 6: Apply the Sealant, please do a better job than I did.
Step 8: Drop the fan in and install the 4 screws.