Ah! So you’ve successfully bought a van and you’re on the first (or second, or maybe fifth) part of your build!

Congrats…that’s huge! But also scary…you’re about to drill and cut holes into your roof. There’s a 99% chance this can go right and a 1% (or 99%) chance that it will go wrong. Not to scare you because I’m sure it will all go according to plan!

But first, what is a van roof vent fan even used for? It’s a faux air conditioner to keep you cool during the warmer days. It also pulls out moisture and smoke from the inside if you’re cooking and don’t want to open all your doors and windows if its rainy or hot and muggy or whatever else the weather could be that you don’t like. It’s a must.

If you’re not sure where to begin, this blog goes over the placement of your vent, why I chose my vent fan, tools you’ll need, and a step-by-step guide so you make sure you get it right the first time around. If reading isn’t for you, head on over to my YouTube channel for a step-by-step video guide.

Tools You’ll Need

This project is one of the more low maintenance parts of the build, so you don’t need much. Here’s what you need.

Having a vacuum of some sort is also helpful for vacuuming up the metal shavings that fly everywhere during the process. Depending on what tools you already have, the total van roof vent installation cost will vary.

Placement of the Vent

Before you place the van roof vent fan, you need to consider what else you plan to have up on the roof. Take into account the solar panels and if you want a roof deck (if your van is big enough). Be sure to measure, measure, and measure again to make sure it will all fit before you start cutting a hole.

I decided to place my vent fan near the front where there was actually a gap in the roof ridges. This will be near my kitchen so it can circulate the air.

My Vent Fan

The vent fan I am using for my build is the Maxxair 0007000K MaxxFan Deluxe Fan with Remote and White Lid. I personally liked the white better because it blends in more with my van.

After reading reviews, this vent fan seemed to be the quietest vent fan and an in-between for the higher-end and lower-end vent fan costs. This one also has a built-in rain cover so it can still run and be open when it is raining.

Installing the Fan: Step-by-Step

Now for the fun part! The actual installation of your vent fan into your van’s roof.

Cut the Fan Opening

Wooo!!! Time to cut a hole in your roof!

1. Wipe Off Your Roof

The first thing you’ll want to do is wipe off your roof with soap and water. It’s probably pretty dirty up there…

2. Measure Out a 14×14 Piece of Cardboard

If you are using a Maxxair 0007000K like me, then you will need a 14×14 inch hole to place the vent fan. Be sure to verify the template size that you fan requires.

Using a cut-out piece of cardboard makes it easier to trace for the hole on the roof.

3. Trace the Cardboard on the Roof

Take the 14×14 piece of cardboard that you just traced and place it exactly where you want on your roof. Make sure you’ve already measured around for the exact placement that you want! Remember to keep your solar panels in mind for this part.

Be sure to center template on the roof area and especially that it is straight. Now channel your inner kindergartener and trace the cardboard!

4. Place a Garbage Bag Under the Roof

To prevent too much cleanup, tape a garbage bag under the roof on the inside of the van. This will catch any loose metal shavings.

5. Drill 4 Holes in the Corners

Once you have the hole traced, you want to drill a hole in each corner of the traced part. Make sure you are drilling right on the inside of the tracing.

We drilled a pilot hole with a 3/8 inch drill and then enlarged the holes with a drill bit that would allow for the jig saw blade to fit.

6. Cut it Out

This is where you have to be veryyyy careful! You’ll place the metal cutting blade onto your jigsaw and then place the jigsaw into the first corner you are going to work with. From there, cut a straight line (emphasis on the straight). You’ll do this around the entire thing until you have yourself a square hole.

To make it easier, we used painter’s tape to tape the half-cut hole (2 sides) to the roof of the van so it wasn’t too wobbly while we did the rest. Once we cut the third side, we taped that part too just to make sure it was secure when the fourth side was cut.

When we were done cutting, we just untaped and pulled the cut hole out! Wa-la! A hole in the roof!

Cleaning It Up

Before you place the flange into the hole you’ve just created, you want to make sure there’s no way for it to rust. With rust being an enemy to the vanlifer, you want to avoid that. Here’s how.

1. File It Down

With your metal file, you want to scrape and scrape (it’s loud) until it seems smooth. Don’t rub your finger on it — that’s an accident waiting to happen.

This should only take a few minutes, so make sure you’re not overdoing it by spending too much time on this part!

2. Use Your Rust Guard Around the Edges

I chose to use Rust-Oleum (looks like spray paint) to spray the edges of the van roof vent fan hole. There’s also liquid ones you can use to paint on (which we will use for the windows).

Spray an even layer on the outside and inside of the van around where there is any exposed metal from the vent fan hole.

Placing the Flange

You’re about a third of the way through the process (and the irreversible part is over with!). So you can continue with the rest of the project after taking a deep breath that you cut a straight hole.

1. Place Butyl Tape Around the Perimeter of Your Hole

Before you put the flage on, you’ll want to put butyl tape around the outside of the cut hole. This prevents any water leakage from occuring after the installation.

2. Stick the Flange Straight on Top

Once your butyl tape is in place, you can place your flange right on top! Make sure you are putting it in the right way for the vent to be seated on the flange.

3. Drill Pilot Holes in Each Hole

Before you take your screws and screw it in, drill small pilot holes in each of the flange holes. This will make it easier for the drill to get the screws in. It also allows you to make sure it stays lined up before drilling it in.

4. Screw in the Flange

Take your screws and screw them all in! Now you have a secure flange.

5. Seal It Up

Before you put the vent fan on the flange, you want to make sure it is leak-proof when it rains or from any other water the world throws at you.

Run the lap sealant around the edges to cover the gap between the roof and the flange. This should be done on the inside of the van for extra protection as well. You’ll also want to cover the screws (on the roof and the inside of the van) with the lap sealant. Be sure to research the proper sealant. I used GE Advanced Silicone 2 sealant.

6. Fit the Vent Fan into the Flange

You’ve made it to the final step!! Well, once you physically do this you will have made it. Unless you’re reading this in real time then yes, you made it! And congrats!

Before you place the van roof vent fan into the flange, you want to make sure you pull the wires out so they hang down. MAKE SURE TO DO THIS! That’d suck if you didn’t.

Anyway, once you fit it into the flange, make sure the metal pieces’ holes line up with the vent fan’s holes. If they don’t, you can wiggle the metal pieces around until they do.

Once they are lined up, you can take your four screws and drill the vent fan into the flange.

You Have Yourself a Van Roof Vent Fan

Now that you’ve installed your van roof vent fan, you don’t have to worry about cutting anymore holes in your van unless you are installing windows. That’s an optional item, though!

Ready for the next step? It’s time to install your subfloor into the van!

If you scrolled down here really quickly because you realized there were a lot of steps, you can watch my Maxxair installation instructions in action in my YouTube video!

**This blog post may contain affiliate links, which means I may receive a small commission when you use these links to purchase items at no extra cost to you. Thank you for your support!

How to Install a Van Roof Vent Fan