VAN LIFE: Installation Guide of MaxxAir Ventilation Fan with Photos & Video on 2012 Ford Transit Connect Camper Van

CAMPER VAN FOR SALE

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CAMPER VAN FOR SALE 〰️

One of the most nerve wracking projects of our van conversions is the installation of the ceiling ventilation fan. In it’s simplest form, the installation required cutting a giant hole in the roof of your perfectly waterproofed vehicle.

But the benefits of a ceiling fan far outweigh the challenges, so we wanted to share an in depth look at our version of this process.

BENEFITS OF A VENTILATION FAN

Essentially, any vehicle converted into a camper van starts as a tin can (or a shell vehicle stripped of its fabric liner).

In our conversions, the dashboard HVAC systems provide heating and cooling, while driving, but are not functional while in camp.

Unlike a home, vehicles are not primarily constructed with the notion of people living and sleeping under its roof. Through the opening of windows and doors, “natural ventilation” is a common method of allowing the exchange of indoor and outdoor air.

Natural ventilation is unpredictable and uncontrollable, and while camping the elements (pressure, wind, rain, temperature, bugs) pose additional challenges.

The addition of a dual operating ceiling ventilation fan allows for the operator to control the intake and exhaust of air pressure within the van; bringing in fresh air and removing musky air.

VENTILATION FAN

Let’s start with the fan itself. This is our third time purchasing a Maxx Air Ventilation MaxxFan Deluxe. The Maxx Air line of products is one of the industry leaders in RV ventilation.

We continue to install the Deluxe model because of the following features:

• built in rain cover

• 10 speed intake and exhaust

• thermostat control

• 900 CFM

• well built, low profile and sleek design

• very quite while running

When a ventilation fan is used in combination with natural ventilation, you can create circulation and optimize comfort levels while sleeping.

We use the Maxx Air ventilation fan in conjunction with our custom, front-door window screens by Skeeter Beeter.

MATERIALS

Maxx Air Ventilation Fan

Ford Transit Connect Roof Vent Adapter (for first generation 2002-2013)

Butyl Tape

3M Fast Cure Auto Glass Urethane

Flex Seal

TOOLS

Safety glasses

Measuring Tape

Masking Tape

Protective Gloves

Scotch-brit Pad

Isopropyl Alcohol

Jig Saw

Metal Cutting Blades

Drill

Step Drill Bit

Metal File

Disposable paint brush

INSTALLATION

Step 1: Cut the Roof Opening

Start by measuring and determining the final position of the vent fan on the roof, ensuring the clearance of the mounting ring, pop top and final trim kit on the interior of the ceiling.

The after market adapter is needed to ensure a waterproof seal, accommodating the roof grooves of the first generation Ford Transit Connect roof. Note the adapter grooves which are designed to lay into the roof grooves.

In the Ford Transit, ensure the fan will sit plum by positioning the fan away from the ceiling cross bar and interior light fixture (see after image taken from inside the vehicle).

Using the adapter as a template, trace the interior of the opening and further define with masking tape.

*Safety glasses recommended. With the opening marked, pierce the roof with a drill and step bit, just inside the cut line, to create an opening for the metal jig saw blade.

Using the jig saw, cut the 14”x14” opening along marked line. Finish by filing the edges of the cut to remove any extra sharp edges.

Unmodified roof

Measuring for placement

Trace and mark opening using adapter as template

Jigsaw

Jigsaw metal cutting blade

After view from inside

Step 2: Prep & Install Roof Vent Adapter Ring / Waterproof

With the opening cut, prep the surface of the roof with a new perimeter of blue tape (about 1 inch beyond the opening edge and scour the surface with a scotch-brite pad. Finish by cleaning the area with isopropyl alcohol.

Using the 3M fast cure urethan, create 2-3 beads of adhesive along the bottom face of the adapter. Flip the adapter over, and fit into opening. Press firmly along all edges.

** In our build, we used the adapter ring as the entry/exit point of our exterior lights. We used a chisel to cut a channel for these wires to sit in.

Using the masking tape as an edge, further waterproof the adapter edge with a disposable paint brush and apply an even coat of flex seal liquid. Allow to set for 15 minutes and remove tape.

Allow Flex Seal to cure/dry for 24 hours.

Scuff surface and clean with alcohol

Apply 2-3 beads of adhesive

3M auto window adhesive

Adapter prepped with adhesive

Create necessary channels for wiring

Mask and waterproof with Flex Seal

Allow Flex Seal to dry 24 hours

Step 3: Mount Ventilation Fan

Apply butyl tape (removing the backing paper) to all four sides of the adapter, overlapping the corners to create a sealed surface. The butyl tape should be positioned in the center of the adapter, so the fan mounting screws pierce the tape on install.

Position fan mounting ring, secure with provided screws.

Install the ventilation fan, allowing electrical wires to fall into the opening, secure with screws.

Reinstall the vehicle liner, and install the interior trim kit as the final step.

Install butyl tape between adapter & mounting ring

Position mounting ring

Secure mounting ring in place

Reinstall headliner & finish with trim ring

What do you think? Will you be installing a ventilation fan in your camper van conversion? Let us know your thoughts or questions below in the comment section.

Happy Camping!

VAN LIFE: 2012 Ford Transit Connect Camper Van Conversion 2.0

CAMPER VAN FOR SALE

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CAMPER VAN FOR SALE 〰️

Back in January, we shared that our fleet of camper vans was growing with the purchase of two, 2012 Ford Transit Connects. With the success of Dolly (our 2010 Ford Transit Connect camper van) during the 2020 spring and summer rental season, we were eager to expand our business and get a couple more units on the road.

We also got a tremendous amount of van life fan feedback that indicated, to us, our process, thinking and design was well received by camper van enthusiasts and conversion DIYers.

We’re in the process of working on FAQ responses about the first conversion and will soon be sharing a digital download of our build out plans.

Are we onto something? We hope so!

We continue to be attracted to the first generation (2010-2013) Ford Transit Connect for a couple reasons:

• cargo area height (the 2nd gen head room reduces)

• their boxier shape (the 2nd gen is more rounded, bullet shaped)

Before we get into the nitty gritty of the camper van conversion, here’s a little background on the vehicles and our plan for the conversions.

PURCHASE CONDITION

Both vans were previously owned by a security company, and in overall excellent condition with relatively low mileage for being nearly 10 years old; 65k and 75k respectively.

For having been commercial vehicles, the exterior condition was great. Minor paint scratched from what looks like a frequent brush with the side of a garage, leaving short imperfections in the paint. We plan to attempt a DIY fix of this, stay tuned.

The interior cockpit/drivers area is in excellent shape. Again, for a contractor/work vehicle, this great of condition is hard to come by when someone is using it daily.

The cargo areas of the vans were equipped with steel shelves and racks, plus the windows had security caging. These existing components have already been removed and sold on Facebook Marketplace, fetching a few hundred dollars we will put back into the conversion.

Both vans had roof racks, which we will keep, as is, and retrofit with exterior storage. The vans also had electrical conduit tubes. We considered using the tubing for a shower system, but in the end decided against it because of the unnecessary water weight and space it would have taken away from storage.

CONVERSION PLAN

The new vans will undergo a similar build-out to Dolly, our original camper van conversion. We will only make minor changes, as we feel the overall design is functional and user friendly for any level camper.

The main conversion components will be broken down into storage, electrical and comfort, but in the 2.0 blog conversion posts we are going to dive deeper into some of the minutia of these decisions and any changes we have on that deviate from the original build.

TIMELINE

The conversion of both vans will take approximately 1 month. We will be setting up shop in a friends barn to aid in the process. The vans are already available to rent on Outdoorsy, so we are working towards a completion date of April 1.

BUDGET

All in, we anticipate the conversions to be roughly $4,000 per van, not including the purchase price of the vehicles. Based on market research, we consider this to be a very frugal conversion. Also, John is not factoring in his time/cost of labor into the budget.

Stay tuned for more posts about the conversions process! Interested to hear more about a particular part of the build? Let us know!

REVEAL: Meet Dolly - Ford Transit Connect Camper Van Conversion

CAMPER VAN FOR SALE

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CAMPER VAN FOR SALE 〰️

John and I are so excited to REVEAL the completion of our 2010 Ford Transit camper van conversion! We’re officially members of the #vanlife movement!

Over the past few months, we’ve shared all about the conversion process including the electrical, storage and comfort amenities added to make the van the perfect travel companion.

✅ Interested in the materials and products we used to complete Dolly’s conversion, check out the full list of here.

✅ Ready to DIY a camper van conversion of your own, just like Dolly’s? Click here to purchase our custom Ford Transit Connect Camper Van Conversion Build & Electrical Plans.

Ford Transit Connect Camper Van Conversion Build & Electrical Plans

Generation 1 2010-2013

PURCHASE HERE

Part of this reveal is also a look into the van’s inaugural trip while we enjoyed leaf peeping in Smokey Mountain National Park.

Now that the hard work is complete, we’re teaming up with Outdoorsy to share the van with campers, like you! Dolly is available for nightly rental with pick up in New Jersey.

Check out Dolly’s full rental listing for all of the included amenities, rates and availability.

Meet Dolly!

Dolly is a cozy, two-person road trip companion; ideal for camping, festivals, romantic getaways or urban adventures.

Besides being adorable, Dolly's best features are her petite dimensions (only 15 feet long) which allow for ease of driving, parking and maneuverability. Any driver would be comfortable navigating Dolly on the highway, back country road, campground or parking garage.

Plus, with exceptional gas mileage (27 mpg), Dolly is ready to make all your travel dreams, near or far, become a reality!

What should you pack? Not much... Dolly has all the basics (plus more) covered! Dolly's standard, rental setup includes sleeping, cooking, camping and leisure accessories.

Just get in & GO!

Want to rent Dolly?

Check out Dolly’s full rental listing for all of the included amenities, rates and availability.

✅ Interested in the materials and products we used to complete Dolly’s conversion, check out the full list of here.

✅ Ready to DIY a camper van conversion of your own, just like Dolly? Click here to purchase our custom Ford Transit Connect Camper Van Conversion Build & Electrical Plans.

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COMFORT Amenities: Ford Transit Connect Camper Van Conversion

CAMPER VAN FOR SALE

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CAMPER VAN FOR SALE 〰️

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We’re sharing the third installment of our Ford Transit Connect camper van conversion and this post is all about COMFORT.

If you missed them, you can backtrack a bit and check out our previous posts on the van’s Electrical setup and the Storage components of the conversion.

But, now that we have all the fundamentals covered, we’re sharing the amenities that make the van a pleasure to use.

✅ If you’re short on time, you can jump to the materials and products we used to complete Dolly’s conversion, check out the full list here.

MATTRESS

On the inside of the van, the most obvious form of comfort is the mattress. For the van conversion mattress, we had a few factors that we had to consider before buying.

Mainly, the mattress needed to be long enough for John (who is 6’ tall) to stretch out completely. With that, we decided on a queen sized mattress but would need to cut the width to custom fit in the wood, bed platform.

Another necessary factor: the mattress needed to be thin enough to fold. If you remember back to our Storage post, the bed platform (and mattress) is only fully extended in “sleep” mode.

In “driving” mode, the mattress is stowed via a hinged section of the bed platform and folding over a portion of the mattress.

We decided on a 6 inch, queen sized Zinus gel-infused, green tea memory foam mattress. A great feature of the Zinus mattress is that it comes in a variety of depths, but in our opinion, any mattress that you are going to sleep on for multiple nights should be at least 6 inches.

With the bed platform as our reference, we measured and cut approx 12 inches of the foam mattress completely off the edge.

For the hinged section, we simply scored the mattress (not cutting all the way through) so the mattress itself would hinge as well.

VENTILATION FAN

Another big expense was a ventilation fan, but after sleeping in the van for just one night, we realized how valuable this purchase was to a comfortable night sleep.

We decided on the Maxxair Ventilation Fan. John cut a hole in the van’s ceiling and mounted it on the roof. This particular vent has a manual vent opening, several fan speeds, thermostat and came in a “smoke” color which looked ascetically better with our grey conversion color scheme.

Even on the coldest night of our inaugural trip, when temperatures dipped to below 40 degrees, our body heat filled the van after a few hours of sleep and the fan kept the air circulating. The van never got stuffy as some campers may have experienced in a tent.

AWNING

On the exterior of the camper van conversion, we decided to install a retractable awning which can be used for sun and rain shade. We did a bit of research and quickly discovered that awnings are very expensive. There are tons of options: mechanically retractable, manually retractable, awnings with sides, awnings with mosquito netting, etc.

We decided a manually retractable awning would be a good investment, and even though costly at $300, still more within our budget. We installed the Rhino Rack Sun Seeker which rolls up into an exterior, nylon zippered case, and provides about 38 square feet of coverage. Just enough for two camp chairs and a small table.

EXTRAS

We also keep a few extra comfort items stored in the roof rack such as our favorite Kijaro folding chairs and a Coleman collapsible side table. Even though most camp grounds have a picnic table and benches, its great to have the option

You can check out all of the sources materials we used for Dolly’s conversion here.

Comment with your thoughts and feedback below!