Our First Five Van Conversion Oops: Learning the Hard Way

1. When you cut out the holes for the roof vents and windows, mind the minuscule metal fragments. They get everywhere and instigate rust practically overnight. We had to remove all the little rust specks on the roof then paint four coats of protective Rustoleum-type product on it. Metal cutting shears as opposed to a jigsaw with a metal-cutting blade would probably reduce the issue significantly.

Roof top rust from the metal fragments.

2. Beware where you’re parked when painting said roof. We were next to a weeping willow on a breezy day. The branches snuck into the paint and did some painting of their own.

3. When installing a Maxx Air fan or similar, and someone recommends adding metal plates on all four sides, you’ll need longer screws than what the manufacturer provided. Then you’ll realize that the four metal plates create a water dam. (Potential leaking problem.)Create a channel that allows the water to escape. But, a better option is to use washers. You will still need longer screws.

4. When installing a new window, be sure your Sikaflex is adequate and even, AND you press all the window edges firmly. Our first one leaked and had to be taken out and reinstalled. Taking it out was brutal. We broke four knives, went through a quart of rubbing alcohol and yards of wire over four hours of removal frustration. Trust me, you don’t want to go through it.

Window removal. Using wire to break the seal.

5. If you’re attending YouTube University, do not rely solely on one YouTuber. Everybody has strengths and weaknesses so you’ll find you need a broad range of ‘experts’ to cover the broad range of tasks needed for van conversion. And watch videos in their entirety before tackling a project. I don’t know if it’s embarrassment, oversight, or stupidity but time and again they make mistakes or leave out vital steps without really sharing the issues and corrections. If/when they do, it’s late into the video or a footnote at the end.