The build out for our van has happened in stages over the past three years as we had downtime between adventures and access to space and tools. The floor was first and we were quick to take off on our Newfoundland adventure. But when we found ourselves housesitting again in Florida later that fall, we took advantage.

After installing some basic wiring, batteries and a charge controller, we installed the MaxxAir Exhaust fan in late 2018. This was primarily to aid with air circulation inside our tightly-sealed space and cut down on the extensive condensation that coated the inside of our metal van each morning. But it’s also vital when we’re cooking inside the van with the doors closed or using our Heater Buddy on cold mornings.

After taping out the square where the fan would ultimately sit, we drilled out the corners. Then using those holes, cut out the square with a borrowed jig saw. This was the first hole we put into the van, and in a way was really, really traumatic. We measured it out several times just to be certain.

This was also the first time we questioned our choice of the Ford Transit over the Dodge Promaster. The curves that made the Ford more aesthetically pleasing than the boxy Dodge, also made installing the fan more difficult. Simply sealing and screwing the flat fan frame to the curved roof would have warped and bent the roof metal and possibly introduced gaps for water entry.

So we bought some PVC 1” x 2” lumber and used a friend’s band saw to shape a curved frame to fit the top and bottom of the roof. This took a good bit of time and shaping with a power sander to get just right. The PVC frames were glued to the roof with marine adhesive and screwed together through the bottom frame. In the end, it worked out and made the whole structure very rigid. Sliding in the fan, sealing it with putty tape and securing it with the included screws, was easy. Then everything on the exterior was caulked again… just to be sure.

The fan has performed well over the past three years. It gets dirty with dust and dead bugs and has to be thoroughly cleaned every so often. But we’ve never had any leaks or water getting in, even during the windiest of rainstorms.

On the downside, the manual controls on the fan stopped working in the summer of 2020. We think a swarm of thrips (very tiny flying bugs, less than 1 mm long) got into the control panel and shorted out part of the circuit board. Fortunately, the remote that came with the unit was still working and we didn’t lose any functionality. If that ever goes out, we’ll have to install a new circuit board.

There’s always room for modification, improvement, or something to repair on the van. That’s vanlife.