Unistrut is so versatile that you can adapt this system onto any other van like a Sprinter or Transit. Looking for more DIY conversion inspiration? Jeremey Adventures’ method for making a DIY rooftop tent is pretty darn simple, especially if you already have a roof rack mounted to your truck or SUV. Pin it! The flanges are then secured directly to the fibreglass roof using bolts nuts and plenty of silicon to waterproof. The previous MMM car – a 2004 Subaru Impreza wagon. Wood can be the least expensive option to go if you're on a budget. SportRack Complete Roof Rack … But, firstly I would throw away the feet, they’re ok but on a wide campervan roof they are at the limit of their reach and I found they sagged quite badly. While clicking these links won’t cost you any extra money, they will help us keep this site up and running! Ours are from Jack Bombay in the US, but you can get lift kits in the UK or from eBay. Make use of the factory specified template. Secondly, the structure is very light and the transverse bars at the front and rear of the rack don’t take being kneeled on by a 120kg man! Ensure its sits properly and no further adjustment is required. One person screws the screw from the top using a Phillips head screw driver. Want to save this DIY van roof rack for later? So I have fitted a roof assist kit, which is just a set of HD gas rams. Sign up to get the latest stories, tips, and information on van life, travel destinations, and more…. An important decision can be choosing between steel, aluminum, and wood. Firstly, if you have a fibreglass pop top like we do, then you need something to attach the rack to and to distribute the load. Top 7 Best Gutter Mount Roof Racks for your SUV, Van, or Truck! Let’s get started! Will your roof rack run front to rear, side to side, or both? Once all holes are drilled, it is now time to mount the roof rack. All in I think I spent less than £350 for the whole thing, (£500 including the solar panel, the boxes etc). Plus it’s exactly how I wanted it. Much less than many of the other offerings available. I wanted a solar panel and somewhere to store either another spare wheel or several cargo boxes, dry bags, etc. This post contains affiliate links, which means we may receive a commission if you click a link and purchase something that we genuinely recommend. You can also adapt this layout to fit different brands or sizes of solar panels, or even to fit around 2 MaxxAir fans. Roof rack brackets. Ours are very heavy duty, but CVC have now produced a lighter version. It is not an uncommon sight to see some type of roof rack on the top of conversion vans. 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. Roof deck instead of rack... Hmm. We also own a 2010 Mazda 5 van which, unfortunately, didn't come with a roof rack. If you are extending the roof rack to the front of the van, consider adding a tee bracket in the middle. Using a measuring tape move the rack into the desired position. . The storage boxes are the Really Useful Boxes reviewed elsewhere on this site and the straps are generic cargo straps from your local DIY or hardware store. This post is going to show you how YOU can make your own pressurized, roof rack solar shower for your vehicle. Van Roof Racks Truck Roof Rack Truck Tent Truck Camper Roof Rails Roof Top Tent Jimny Suzuki Land Rover Discovery 2 Jeeps. Maybe a smidgen shorter. All of these things must be considered when determining how to design the roof rack. For our solar panels, we used U-bolt to secure them to the round pipe. Enter your email address to follow this blog and receive notifications of new posts by email. Insert bolts, provided with your van tech roof mounts, into your bottom brackets pointing upwards. AA-Racks Model X37 Heavy Duty Rain-Gutter Van Roof Rack Round Bar Three Bar Set Steel Matte White. Simply screw together the poles with the tees with the flanges and viola! Our rails will ultimately be used to attach a roof rack to the van and support solar, an awning etc. 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) It's a simple and cheap way to make a solid roof rack. First step, establish your needs. 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. 4.5 out of 5 stars 131. A fully custom, DIY solar panel roof rack for a Promaster van! Out of a love for travel, we met one snowy Christmas night in Estonia. Attaching the rack permanently to the van is the scariest part of the whole build. For our solar panels, we used U-bolt to secure them to the round pipe. I then bolted the roof rack through a set of roof bars, just like normal cars use. Using a flat head screw driver, assemble the roof rails to the top of the car by sxrewing the side rails and the cross bars together. ... Then, you can just use straps or bungees to attach the rack to the car/van, and leave those attached as long as you need the rack in place. Basically, Jeremy just gets a Kamp-Rite Overside Tent Cot with a Rainfly and then mounts the whole system to the top of his Land Cruiser. We have drawn together a basic picture of how each supporting piece should look. I used CVCs aluminium bars, but any generic ones from your friendly car accessory store will also work. If it needs significant work I will remove it, do the work and refit it. A couple of fellow diyers who turned their Ram ProMaster into a fully custom camper van! This step requires two people. This is fine when you have a solid roof, but in our case we want to fit our rack to the fibre glass pop roof, which is strong but shouldn’t be overloaded. The Vantech H1 system uses 2″ X 1″ rectangular bars. Saved by Carol-Ann Mulkey. The Completed DIY Van Roof Rack. I do not load or unload unless it’s fully down on the gutters. DIY Rooftop Camper Made From The Simplest Of Materials. Roof rails are a handy addition to any Sprinter but not all vans were ordered with the rails factory installed. I'll measure this am. Measure the roof two or three times to confirm the measurements because once you cut the steel, there is no going back. don’t forget it when entering ferries or passing under low bridges or entering underground car parks! Set the assembled rack atop the vehicle. These are available to buy as options when you place your order. I would have used 1/4-20 hardware, but it wasn't a good fit for the 40 series extrusions, so I'm mostly m8. But I am considering the strength of the fibre glass. Let us know below! I bolted through using stainless steel fittings and big washers, but you could use U bolts and bolt around the bars instead. Thank you for your support! Highland 2006200 Black Heavy-Duty Bar Carrier. By DoItYourselfRV Car Campers, DIY, ... A roof top camper usually consists of a rigid bottom and heavily reinforced tent. Having removed the feet, I needed a method to mount it. He helped us design a DIY van roof rack for our specific needs and hopefully we can do the same for 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. Sprinter Van DIY $200 Roof Rack and Deck | Vanlife Hack. We decided to take matters into our own hands and so should you. Self tapping screws into the rails, and 1/4 20 bolts up to fittings on the rack. Does your roof rack sound like a wind tunnel while driving down the highway? We have a wide selection of Van and Truck Racks for most models of pickups and vans. perusing the web for a couple of hours and trolling YouTube for instructional videos) we still were at a loss for how we were going to construct and install a roof rack. Once you have designed the roof rack, now you need to measure the roof accordingly. 2. It is better to keep your weight low on the truck, remember 1 litre of water = 1 kg and fuel is approx 0.8kgs. 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. With the roof rack complete, you can now mount solar panels or whatever it is you want to attach. 462. However, if there’s nothing on the roof, it makes closing the roof a practice ground for a trapeze artist! I then bolted the roof rack through a set of roof bars, just like normal cars use. Thule Roof Rack Gutter Mount Foot Pack. Thanks for wandering with us! The “U” cups the bar and is bolted into the solar panel itself. The roof bars will connect to the roof with a tee junction, ‘nipples’, short bits of pipe which connect to the junction at one end, and screwed into flanges at the other. While there are plenty of options for standard cars and SUVs, finding one for a high fiberglass topped conversion van was little more difficult. I cannot tell you the number of times, we started a project only to find out that we did not have all the pieces. Everything is bolted up using marine grade stainless steel nuts and bolts, or aluminium pop rivets. I have imposed a rough 50 – 60kg cargo limit for the roof which is well inside the roof rack and bar limits. Do you want the roof rack to extend the length of the car or only the cab? Drill a hole slightly smaller than the screw to bolt the flange to the fiberglass roof. Make sure to tighten the bolts as securely as possible to avoid losing a panel (or a roof) in your overlanding journeys. 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. However, steel and aluminum are more durable and stronger, so they will last you a lot longer! The “U” cups the bar and is bolted into the solar panel itself. Using our van would be more economical to haul skis, a kayak, and other camping equipment around. So as we only usually want to store wet or infrequently used kit and a solar panel, neither of which is heavy, or perhaps a spare wheel, we went for Aluminium for lightness and modified it to suit our needs. Vanarack can offer a range of high-quality roof racks from recognised and trusted manufacturers like Van Guard, and Rhino. Especially considering our particular needs and sizing. 99. No additional mounts are used or required with this custom DIY van roof rack. Just ensure the bars are for gutter mounting, as the feet are needed to work with the brackets. Hardware is important. I've got about $400 in it. Below is a How-To article on installing the factory roof rails so you can mount any number of items to your roof. Rhino-Rack RTS523 Sprinter Van Roof Tracks for 144″ Sprinters The kit includes two, 113 1/4″ extruded aluminum tracks, black plastic end caps, and all the mounting hardware. Deciding on flooring in a van is difficult. After conducting thorough research (i.e. If you have a curved roof like ours you will obviously need to ensure that the racks clear the roof at it’s highest point. These days, it’s rare to find a converted van without some form of rack mounted to the top. 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