At some point everyone who modifies a van will have the day where they cut a hole in the metal skin of the van for a window or a vent. Today is not that day.

But, that day is coming. For me, it will be a 14” square hole in the roof for a fan. Some of the longer wheelbase vans get two vans, one fore and one aft. I will be adding just one, in the back above the bed.

Today’s task was to prepare a wooden support frame that will be inside the van on the perimeter of the fan. Screws will be driven into this frame from the outside of the van through pilot holes in the sheet metal. This provides for a sturdier attachment than just the metal alone. Later in the build this wooden frame will be covered/hidden by a plastic trim piece, and the ceiling. As you can see, the Kreg pocket hole jig made my square look completely professional.

Once I prime and paint this, I’ll be all set to cut into the van. As the second big thunderstorm of the day passes through, the fan install will happen only when a sunny morning and a day off from work happen at the same time. Hopefully soon.