Installing a Ceiling Fan in Our Bus Conversion
Our bus has it’s very first appliance: a MaxxFan 4000K Ceiling Fan Vent! Emmett and I spent a sunny weekend installing it into our bus ceiling. We were honestly pretty nervous to cut a large hole into the roof but in the end everything seemed to be very secure and watertight. Here’s how we did it!
Disclaimer (as always): We are not professionals. We are learning this as we go and I created these posts merely for those interested and to potentially offer guidance to other bus conversion novices like ourselves.
Installing the Fan
Step 1: Cutting the Hole
Jig sawing!
All done!
Emmett and I began this step by first deciding exactly where we wanted the Maxxair vent fan to be installed. After careful consideration, we decided upon placing it above our future bed. Then we measured the fan and traced those measurements onto the ceiling. At each of the four corners of that fan-shaped tracing, we drilled a pilot hole. This not only allowed us to see the location of the fan from the roof but also provided starter holes for our jigsaw. After drilling, we crawled up onto the roof and used a straight edge to trace out the square again between each pilot hole. Then Emmett used our RYOBI jig saw to cut the hole and voila (see above)!
Step 2: Prepping the Ceiling for Install
Bad quality shot of our overnight clamp set up - my phone camera dislikes bright sunlight.
Once the hole was cut, our next step was to strengthen the perimeter of the hole on the ceiling with some spare pallet wood. We did this in order to give the fan a better and thicker base to be screwed onto. Emmett and I cut the pallet wood to size with our circular saw and then glued it onto the ceiling. To get the glue to adhere properly, we clamped each piece onto the ceiling (see above). Then we left the clamp setup overnight, using a spare piece of scrap metal as a temporary hole cover to keep out weather and critters.
Step 3: (Actually) Installing the Fan
The fan’s edges covered in butyl tape and nearly ready to be put in place.
The next day, the pallet wood was well-adhered to the ceiling and we were able to get started on putting the fan in place. First we lined the lip of the fan with butyl tape - which is basically a thick watertight tape-like adhesive (see above). Then, for extra comfort/security we also added some roof sealant on the gaps between the tape. From there we put the fan in place and then using the kit screws, drilled the fan through the ceiling and into the pallet wood. Last but not least, we covered the screws with more roof sealant to keep all aspects of the fan watertight. And then we were done!
Finished fan as seen from the outside.
Finished fan as seen from the inside.
Materials Used on this Project
Cutting the hole
Measuring Tape
Carpenter’s Pencil
RYOBI ONE+ 18V Cordless Drill
Dewalt 3/8-in Pilot Point Drill Bit
RYOBI ONE+ 18-Volt Cordless Orbital Jig Saw
Bosch T118B Steel T-Shank Jig Saw Blade
2. Installing the Fan
Pallet Wood
Premium Multipurpose Loctite Construction Adhesive
Three 4 inch C Clamps & one 3 inch 3-Way Edging Clamp
Dicor BT-1834-1 1/8" x 3/4" x 30' Butyl Seal Tape
Dicor 501LSW-1 Epdm Self-Leveling Lap Sealant - 10.3 Oz
Maxxair Vent Corp White 00-04000K Maxxfan Plus Vent 14" 12V
RYOBI ONE+ 18V Cordless Drill