5. Roof Rack Installation
I am pretty early in my van build but as I think about the design and try to plan where exactly things are going to go, I started to think I may need to get the roof rack figured out and installed as it could have bearing on other installs. One example is the location of the Maxx Fan. I know that I want to center this somewhere between the galley and the third seat inside the sliding door, but the specific location may be determined by the roof rack, or by what may be mounted on the roof rack, like solar panels. I would hate to cut a hole in my roof for the fan and find out later that I cant maximize space for my solar system or I jeopardized some other plan because my fan location was off by a couple of inches. For that reason, I felt that the roof rack should be the next logical mod for my van build.
Selecting the Right Roof Rack
Choosing the right roof rack can be a bit intimidating at first. There are a lot of great looking options available and some are better suited to specific purposes than others. The intent of my rack is to provide a versatile base to mount an LED lightbar, perimeter spot lighting, solar panels, possibly an awning, and some of my adventure gear where feasible.
As you consider your perfect roof rack, think about your specific needs and the primary use for your rack. If you plan to transport heavy-duty equipment, opt for a rack with a high weight capacity. For lighter gear, a simpler design might suffice.
Flatline Van Co
After evaluating my needs, I decided on the 144 High Roof Standard Rack from Flatline Van Company. The companies products have a great reputation for their quality and durability which extends to their roof racks. The Standard rack has a wide footprint that gives you 53.4 inches of useable space in width. This is an important spec to consider and cross reference with the solar panels you intend to use or any additional gear or hardware you intend for this space. The 53.4 inches works within my intentions as it would fit the largest solar panels that I am currently considering. This rack is very versatile and meet my needs of flexibility to allow mounting options for just about anything. It can even accommodate decking though I don’t think I will need that. The other features that caught my eye were the front wind deflector, and the removable panel to allow the installation of a side mount ladder. The ladder was already hot on my radar and after thinking about it deeper I felt it made sense to move it up the priority list as it will certainly get used and be a big help during any installs requiring roof access. I’ll talk more about the ladder in the next article.
Roof Tracks
To mount or install anything on the roof of your van you need to have roof rails, or roof tracks. Most vans come from the factory with these installed. If your van does not have roof tracks, you will need to address that first. My van was one of the unlucky ones that came without. Tracks are available for most makes and models from Vantech USA and are relatively inexpensive.
Installing Vantech Roof Tracks
Installing Roof Tracks is pretty simple as the mounting holes are already pre-fabricated from the factory. The holes are plugged with plastic caps and water proof putty.
We start by locating the plugs and removing them by heating the plug with a blow dryer to soften the factory putty, then prying them up with a body clip tool. Once the plug is loose, we can tap the underside of the plug from inside the van to knock it out.
After the plugs are removed we clean the entire channel where the roof track will mount and ensure all the old putty is removed.
We then prepare the roof tracks by applying the peel and stick gaskets to the underside of the rails.
Next we place the rails in the roof channels and align them with the appropriate mounting holes. We secure the tracks in place using the included hardware.
Last, we push the end caps into the ends of the roof tracks and tighten all the hardware. (Note: If you are installing your roof rack or ladder right away, hold off on installing the end caps as you will need access to slide the rail nuts in.)
Flatline Line Van Co Roof Rack Install
Roof rack installations can vary by model but will start with sliding the rail nuts inside the roof tracks and aligning them with the mounting locations of the rack. If you are planning to install a side mount ladder, install the rail nuts for the ladder mount at this time as well to keep from having to undue some of your work later.
For the Flatline Van Co Standard rack, the next step is to mount the side rails to the rail nuts, and install the connecting plates.
Once the side rails are up, we layout the crossbars in the general area where we think we want them and secure them to the side rails. (Note: This may get changed a few times as you continue your build. To get close, keep in mind where your Maxx Fan and any other roof top equipment will go. This can be tricky and is why I opted to install the roof rack prior to finalizing the location of my fan.)
Next we assemble the front fairing and install it on the front of the roof rack
We then assemble the rear spoiler and install it on the rear of the roof rack
The last step is to make any final adjustments and tighten everything in place
Post-Installation Tips
Here’s a couple quick tips to keep in mind with the new roof rack.
A roof rack is exposed to a lot of wind and vibration so be sure to keep an eye on it and re-check the tightness of all screws and bolts. Especially as a new install, but this is also good to do from time to time and after long trips or when carrying heavy loads. A quick inspection before each adventure can prevent potential issues.
Be mindful of your van's increased height with a loaded roof rack. Low-clearance areas such as parking garages and tree branches pose risks. Familiarize yourself with the van's new dimensions to avoid potential damage. I measured my van’s height with rooftop gear and keep a quick reference card posted in the cab.
Installing a roof rack on your Sprinter van can open up a bigger world of possibilities for every adventure seeker. It adds functionality and options for a plethora of additional features from awnings and lightbars, to solar panels and showers. It also increases your storage capacity options which can enhance your overall van experience. With the right roof rack, your van can transform from a mode of transport into a reliable adventure partner. Stay tuned to see how my rack is utilized and if I end up putting its versatility to the test!
