Bus Build: Fan Install on Curved Bus Conversion Roof – S03E16

By Mela & Don | Bus Conversion

To help ventilate our bathroom we chose the Maxxfan Deluxe by Maxxair. It has an intake and exhaust fan, an electric lid opener and remote. We chose this model as you can set it to auto function. When the temperature increases past the maximum degree (whatever you choose to set that to) it automatically turns on and begins venting. The lid also has a hood that will keep rain out, so you can use it come rain or shine.

We made a wooden frame for the fan to secure it to the beams on the ceiling of our bus in the same way that we made our skylight frames. Check out this blog for directions on how we made the frames. The only difference was that the fan is 14 x 14 inches which is smaller than our skylights. We made the 14x14 frame but added an extra ladder like piece to secure it to the roof beam.

We jacked the frame up into the ceiling and marked off where to cut the hole. Used an angle grinder with a diamond blade to cut the hole, then glued and screwed the wood frame into the ceiling. We used a few more screws this time then the skylights needed, as the fan sticks up above the surface and will have to withstand the force of the air as we travel.

Up on top of the roof we used butyl seal tape to secure the fan frame (provided with the Maxxfan) to the roof and a silicone sealant to the bottom and edge of the mount to ensure it was watertight. We used 16 screws to secure the fan mount into the buses aluminium roof and the wooden frame we created.

The Maxxfan frame bends to the slight curve of the bus roof quite easily however once you slide the actual fan into this, it’s a little trickier to get the fan to fit to the curve. It is designed to sit flush with a flat surface. With a little persuasion however we were able to screw the fan in place.  Once again we used a sealant to seal the screws and prevent any leaks.  

It was a fairly simple process to install. We hooked it up to a power source to test it and were very impressed with how quickly it began to cool down the bus.

 

Up Next
Juggling multiple projects and with limited opportunities for getting supplies, thanks to the Covid19 Pandemic, we took the opportunity to learn cabinetry skills and create our TV lift and fireplace cabinet.

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Maxxfan Deluxe by Maxxair
Powerful 10-speed intake and exhaust fan. Thermostat to control room temperature. Provides over 900 CFM to keep you cool and comfortable. Fits all standard 14" x 14" roof openings. Electric lid opening with remote control. Fan runs with lid closed to circulate air (Ceiling Fan Mode).

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Rustoleum Primer
Ideal for use on ferrous, non-ferrous metal, wood, concrete, masonry and other such surfaces to prepare surfaces for painting, provide rust protection and a tough finish that withstands weathering. We painted this onto our wooden frame to protect that wood from any moisture.

 

Butyl Tape
Ideal for sealing uniquely shaped joints, in our case - the curve of the buses roof. Apply along unusual patterns. Because the sealant is on a continuous roll, installer can work fast and be virtually assured that there are no skips or runs in the seal

 

Guerilla Glue Silicone Sealant 
Best for sealing gaps or cracks between two surfaces; works on window, door, kitchen, bath, gutters, auto, marine and more.  It dries a translucent clear and won't yellow, shrink or crack.  It is 100 % waterproof, and mold and mildew resistant.  We used this to seal the edge of the fan frame against the roof.

 

OSI QUAD Window, Door and Siding Sealant
OSI QUAD bonds without a primer to most common substrates like cedar, painted or stained woods, fiberglass, vinyl, coated aluminum, steel, metal, brick, masonry and concrete. With resistance to UV and extreme temperatures (20°F to 120°F) and proven wet surface application, OSI QUAD is the versatile and durable choice for professional contractors. We used this to cover the screws and make sure those holes wouldn't leak.

 

Teks 2-3/4" Wood-to-Metal Self-Drilling Screws
For attaching wood to thicker 20-12 gauge metal. Special winged fasteners ream a hole in wood preventing thread engagement during drilling. We used these to secure our wooden frame into the buses ceiling beams.

 

Teks 2-3/4" Wood-to-#9 1-Inch Teks Sharp Point Roofing Screws Metal Self-Drilling Screws
Teks hex washer head sharp point roofing screws with washer provide secure, weather sealing for all metal to wood applications, stable hex head & sharp point allow fast penetration. We used these to secure the fan's frame to the bus roof and into our wooden frame below.

 

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About the Author

Mela and Don are sharing their journey as they make conscious decisions to live a more healthy, environmentally friendly life together.

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