Progress Update
It’s been a while since the last update but we have actually done some work on the van. I only have a few more weeks of my current university module left and then we have a decent gap until September to get into the project more.
As you will see in this post, we have done the first “big” job on the van which was to install a vent. Additionally we have done a couple of smaller jobs to make things more comfortable day to day, this includes:
- Purchased some new floor mats for the cab
- Replaced the broken window winder
- Cleaned the Seat Belts (to help reduce sticking)
- Put up a couple of battery powered lights
- Relocated a loose roof rack
- Got a 2nd hand drive away awning which we cleaned/aired
- Installed a Little Tree smelly (very important)
Vent Installation
One of the jobs we wanted to get done first was to install some form of vent to allow some airflow and reduce any condensation build-up. Having a vent also just helps make the van more comfortable to work in going forward.
After much to-ing and fro-ing between installing a fancy sky light, 12v motorised vent or a simple wind driven solution, we decided to go with the latter. With this being a first build and a relatively small area, we deduced that a rotating roof vent paired with a sliding window would be adequate airflow and natural light for our use. We picked one up from ebay along with a 95mm hole saw and went about the task of fitting.
Tools Used
- AVT Rotating Vent
- 95mm Bimetal Hole Saw
- Drill
- Marker and Tape Measure
- Metal Files
- Sand Paper
- Butyl Tape
- Sealant
- Rubbing Alcohol
- Hammerite Kurust and Paint
- PPE (Gloves and Mask)
- Vacuum Cleaner
Drill a hole in the roof
We started off by identifying where we wanted to fit the vent and cleaning the area inside and out with soapy water before drying and de-greasing with rubbing alcohol.
We used a tape measure and marker to get an accurate centre to drill our rather big hole. A small pilot hole was drilled through the roof before letting loose the 95mm hole saw. I did plan to drill the hole partly from the inside and outside but the saw went through the roof much easier than I expected from the inside but still made a pretty clean cut.
Clean-up and Treat
With a nice fresh 95mm hole in the roof of our van we went about cleaning up the edges with a file and sandpaper before treating the raw metal with Hammerite Kurust and Paint to HOPEFULLY avoid any rust issues. The hole cutting, filing and sanding created a lot of metal shards which needed to be cleaned up thoroughly so they wouldn’t tarnish and rust any of the van.
Seal and Fit and Seal (again)
After leaving the Hammerite to dry for a few hours, we were ready to fit the vent. Butyl tape was applied around the edge of the hole from the top/outside of the van before dropping the vent through and fitting from the inside. The vent we purchased uses a really simple sandwich style mounting system where a ring is screwed in from the inside, pulling down on the vent and sandwiching the unit to the roof. The butyl tape was used instead of the stock seal because it conforms to any defects in the van roof and should offer a better seal. Due to how butyl tape pushes out, it took quite a bit of work to tighten the unit up, often involving swear words and a break. Once everything had settled and the unit torqued to FT, some sealant was applied around the edges of the vent to finish the job (this step was probably overkill as the butyl tape alone should do the job).
Job Done
The vent was left an hour or so to dry before checking it was still fully tight and sealed. After that it was just a case of putting the airflow plate on and cleaning up, job done!
About the Author
