Drill a hole slightly smaller than the screw to bolt the flange to the fiberglass roof. 170" Vans come with 6 mounting brackets, 5 crossbars, and all hardware needed to install the rack to your van… I wanted a solar panel and somewhere to store either another spare wheel or several cargo boxes, dry bags, etc. Simply screw together the poles with the tees with the flanges and viola! However, steel and aluminum are more durable and stronger, so they will last you a lot longer! Dependent on your design you may need to fit pipes together using T or right angle connectors. After conducting thorough research (i.e. Everything is bolted up using marine grade stainless steel nuts and bolts, or aluminium pop rivets. A fully custom, DIY solar panel roof rack for a Promaster van! The design itself couldn’t be more simple. So, to improve access, I removed the rear one. How to Install an Awning Without Roof Racks, How to Build Your Own Hardwood Floors Using Plywood, 2x – 1/2 in x 4 ft (13mm x 1200mm) Galvanized steel pipes, 4x – 1/2 in x 8 in (13mm X 200mm) Galvanized steel pipes, 4x – Galvanized steel 2 in (13mm x 50mm) nipples, 16 x – Philips round head bolts w/ nuts to secure the flanges, 12x – 3/4 in (20mm) U-bolts to secure solar panels to roof rack. Our rails will ultimately be used to attach a roof rack to the van and support solar, an awning etc. If it needs significant work I will remove it, do the work and refit it. 4.5 out of 5 stars 131. I've got about $400 in it. Our racks are designed to be the Ultimate DIY Van friendly system! All of these things must be considered when determining how to design the roof rack. FREE Shipping. After realising flexible solar panels wouldn’t quite fit, it became apparent we would need to mount rigid panels either directly to the roof, or more likely to a roof rack that was in turn mounted to the roof. Deciding on flooring in a van is difficult. Now you can play around with the configuration. DIY Road Shower ROOFTOP SOLAR SHOWER SPECS: Capacity: Approximately 18.5 Liters (5 gallons) Total Length: Approximately 2.3 meters (7.5 ft) Weight When Full: Approximately 21 kgs (46 lbs) Sprinter Camper Conversion Cargo Van Conversion Sprinter Van Cargo Roof Rack Van Roof Racks Diy Camper Camper Van Motorhome Platform Deck. Roof rack brackets. The Completed DIY Van Roof Rack. Ours are from Jack Bombay in the US, but you can get lift kits in the UK or from eBay. Make sure to tighten the bolts as securely as possible to avoid losing a panel (or a roof) in your overlanding journeys. Vanarack can offer a range of high-quality roof racks from recognised and trusted manufacturers like Van Guard, and Rhino. Of course, what you really need is a solid safe and secure roof rack. The fittings aren't cheap, but I've changed the configuration a couple times for very little. Thanks for wandering with us! The unit mounts securely to the roof of a car or SUV. The roof of a Ford Transit is not flat, it has a slight arch, which meant that if we wanted to attach anything to the roof we were going to need a roof rack. Mounting solar panels on our curved van roof was one of the more puzzling challenges we faced during our build. Drilling holes into the van is not something you want to get wrong so be sure to measure twice drill once! The rack is incredibly lightweight and easy to assemble. I cannot tell you the number of times, we started a project only to find out that we did not have all the pieces. Take some time to align them correctly before drilling holes and you won’t have a set in the wrong place…… . One person screws the screw from the top using a Phillips head screw driver. Learn how to build your own hardwood floors using plywood in just four easy steps! Roof deck instead of rack... Hmm. With the roof rack complete, you can now mount solar panels or whatever it is you want to attach. Out of a love for travel, we met one snowy Christmas night in Estonia. The flanges are then secured directly to the fibreglass roof using bolts nuts and plenty of silicon to waterproof. We needed to design a DIY van roof rack, from cheap materials available from the hardware. Don’t go mad filling your roof with jerrycans! In this episode, we decided build our own roof rack and deck for your Sprinter for around $200. I'll measure this am. This post is going to show you how YOU can make your own pressurized, roof rack solar shower for your vehicle. The next thing that became apparent was that we would need to be able to create a custom roof rack suitable for our vehicle and needs. DIY - Roof Rack Fairing / Wind Deflector. Pin it! We have drawn together a basic picture of how each supporting piece should look. Eighteen months later, we quit our day jobs in search of a more nomadic life style. Just ensure the bars are for gutter mounting, as the feet are needed to work with the brackets. A DIY Roof Rack: Make your Small Car Carry Big Stuff. Instead of buying an expensive roof rack system, I commissioned a simple steel rack at the SLO MakerSpace, and then installed it on the fib… The second person holds the bolt in place inside the van, so it does not move when tightening from above. However, if there’s nothing on the roof, it makes closing the roof a practice ground for a trapeze artist! 99. Don't have the dough to buy a wind deflector / fairing? Camper Van Conversion With a No Weld DIY Roof Rack! This homemade roof rack system cost only $50. As we only wanted to mount three rectangular solar panels, our simple design required just two 4 foot roof bars running front to back on either side of the vehicle. There is nothing like getting halfway through your project and realizing you forgot something. Have you had a go at making your own DIY van roof rack? Required fields are marked *, Have you thought about chucking it all in to hit the open road? 1. These are available to buy as options when you place your order. The previous MMM car – a 2004 Subaru Impreza wagon. Using a measuring tape move the rack into the desired position. Using our van would be more economical to haul skis, a kayak, and other camping equipment around. Drilling the roof rail. Truck & Van Racks. My rack is about the same height off the roof as the factory rack. The roof rack significantly increases your height, especially when loaded…. We decided to take matters into our own hands and so should you. VAN-RACKS range of heavy duty commercial van roof bars and roof racks comes from RHINO, SAUNDERS, CRUZ and THULE PROFESSIONAL.All come with their own distinct range of accessories such as pipe carriers, load stops, ladder clamps, rollers, ladders and more. Plus it’s exactly how I wanted it. Steel has always been a popular DIY roof-rack option, as it is easy to acquire and relatively inexpensive. Among many other awesome features they built a custom roof rack out of Maker Pipe and conduit! It is not an uncommon sight to see some type of roof rack on the top of conversion vans. The Vantech H1 system uses 2″ X 1″ rectangular bars. We hope you’ve found this post useful. Saved by Julius pepperwood. Description. I used CVCs aluminium bars, but any generic ones from your friendly car accessory store will also work. I then bolted the roof rack through a set of roof bars, just like normal cars use. For this DIY roof mount, you can find all the materials we used listed below and purchase them online in advance from Home Depot. Saved by Carol-Ann Mulkey. Half inch galvanized steel pipes form the bars of the roof rack. Hardware is important. Once you have double and triple checked your measurements, use a pencil, draw a circle around the flange and in each of the screw holes. Especially considering our particular needs and sizing. Thank you for your support! Thankfully, Charles, the resident family handyman/engineer, dropped by at the perfect time to help us to create our very own DIY custom roof rack, suitable for permanent installation to all vans, even those with a curved fiberglass roof. Ours are very heavy duty, but CVC have now produced a lighter version. I do not load or unload unless it’s fully down on the gutters. They simply sit in the rain gutter when the roof is down, spreading the load, especially when you climb up to load the roof rack. 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