Building a ROOF RACK for 580W of Solar Power!
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- Опубліковано 21 січ 2025
- We designed and built a roof rack for our Ford Transit camper van conversion to hold as MUCH solar as possible while still having room for our Nomadic air conditioner and Maxxair fan. It's super low profile with a wind fairing up front that should, at our best estimates, net us a 3 second decrease on our 1/4 mile time.
Special thanks to Unaka Gear Co for sponsoring this video and for working with us to bring this idea to market. They've got all kinds of other roof rack solutions (and more) at their site: unakagearco.co...
➤Shop the EXPLORIST.life Store: shop.explorist.life
➤Shop Battle Born Batteries: battlebornbatte...?afmc=explorist_bb67
➤Binge the Transit Van Build: • The Ultimate Camper Va...
Here are some additional resources that you may find helpful with planning and installing your DIY Camper:
➤DIY Sprinter Camper Van Electrical Install - Full Tutorial: • DIY Sprinter Camper Va...
➤DIY Camper Solar Wiring Diagrams: www.explorist....
➤How to Perform a Power Audit: • How Much Solar Power D...
➤Basic Parts & Components of an Electrical System: • Basic Solar Parts Need...
➤How to Cut Wire: www.explorist....
➤How to Strip Wire: • How to Strip Wire from...
➤How to Crimp Wire: • How To Crimp Wire Lugs...
➤How to Make MC4 Connectors: • How To Make MC4 Connec...
➤How to Wire Solar Panels in Series-Parallel: • How to Wire Solar Pane...
➤How to Crimp Wire Ferrules: • How to Crimp Ferrules ...
➤How to Wire an AC/DC Breaker/Fuse Box: www.explorist....
*EXPLORIST.life x Unaka Gear Co Roof Rack:* unakagearco.com/products/ford-transit-roof-rack?variant=45730334736603/?dt_id=105323
Another good idea is to put a small strip of 3m clear paint protection film. Even the rubber gasket has some vibration that still has contact with paint. The film will eliminate the actual contact to paint. Plus dust gets built up under the gasket over time. The film does the job 🤙🏼
Sure! Another good idea there.
One of the cleanest solar roofs I have ever seen. Functional AND Beautiful. Bravo!
Hey, My Channel! I appreciate that. Thanks for watching! 🙂😀
If you've got a Transit 148" with a high top like us and are looking to purchase the roof rack shown in this video, just reply to this comment and I'll make sure you get the info you need. We are working on the order page and will have it available in the next few days. Thanks for watching!
Ordered a transit crew two weeks ago.Maybe taking delivery March 2023? I will be looking for a roof rack!
Please put me on the list.
Definitely interested!
I would love to have this on my van I have the high roof extended version.
Please, put me on the list. Thank you
I wish I had this available when building my roofrack. Thanks for innovating!
Absolutely amazing I didn't get to watch the whole video but I saw the first and I get to see the rack I'll look at the bills when I have time but just awesome teamwork
Glad it was helpful. Cheers!
Thanks so much for putting this series here on UA-cam, I'm really enjoying the simplicity and visual aspect of your explanations (mix between a kinesthetic and visual learner) and the way they make me feel like I can do a lot of this stuff myself when I get my van next year, which after watching so many other videos, I did not feel like at all (especially electrical, which I was just totally confused about).
Hey, Matthew Appleby! I appreciate that. Thanks for watching! 🙂😀
@@EXPLORISTlife A question about the Ford roof top: Could you have fit 3*200w Renogy solar panels 1650 x 670 x 35 mm / 64.96 x 26.38 x 1.38 in and 2 max air on it without the AC and roof racks? I'm curious about a 3 lithium 600AH battery system and what the max solar you could get out of the rooftop may be to charge this kind of system. Also is there a reason you picked AC for this van over a 2nd fan, as I know Australia gets really hot in summer and really not sure between internal/external AC or just getting 2 fans. I noticed you did not cut a spot for ventilation for a shower, is this not needed as there is no risk of condensation leading to mold? Thanks if you can answer, but understand if your too busy 😄
Really nice congratulations looks beautiful
excited to see the panel setup on this :)
So, are you planning at the end of this build to post the final Retail cost? Since we live in a real world it would be nice to know what it would cost to build out a van of this type. Thx.
Of course!
Does the fairing gasket come with the kit?
Thanks for watching! The gasket does indeed come with the roof rack. We really liked the concept of having the fairing come all the way down to the roof line, so we decided to include the gasket. After our maiden voyage from Steamboat Springs to McCall Idaho this weekend, we averaged 17MPG, which I'd like to think that the low fairing angle helped with.
I have a roof rack installed already, I think the gasket is a great idea! Is there anyway you can post a link to purchase a gasket separately like the one you are using?
Thanks
Unaka is going to have that available soon so you can buy 5-6ft of it, but until then; this is what we used: amzn.to/3zBPneU Pay special attention to the edge width. Our wind fairing is 3/16" so we used 3/16 edge gasket. 1/8" edge gasket would not fit.
Another great video! thanks
Use a Dremel tool with a sanding drum to adjust roof mount holes. Using a vacuum will keep filings from falling inside. Then a cotton ear swab to touch up paint.
Yeah, there are 1,000 ways to do what we did with similar results. If we were doing it over again, we'd do it the same way we did it the first time.
I see they sell the gasket.. Awesome..
Love your videos
Thanks! 🙂🙌
Do you have any information on where exactly the fan is installed? I have the exact same van and rack I would like to have a set up like this.
If the roof rack was tall enough, how much clearance would you need to cover AC unit to not hinder ac functionality? That way you can have maximum amount of solar panels?
Hello, what is the complete height clearance of your van?
Any chance you know the usable width of this roof rack? I am considering purchasing this kit but I’m having trouble finding the dimensions online. Thanks!
The install directions are a bit different now. Feet first, then 80/20, then the sides slide on. I am kinda installing this same setup, but doing dual max air fans using the 55 watt panels and the special crossbars. But, how did you decide exactly where to put that max air fans? 9.5 inches from the air unit had to come from somewhere. I might have to put the rack up, then test fit the solar panels and cross bars to figure out where the fans go. To get your measurements for cad how did you know where the start/end of the rack would be without assembling it? You said you set the rail ends 10.5” back from the feet, but that also must be specific to the solar layout, right?
The measurement was locked in by seeing where the air conditioner would fit between the cross braces then measuring the front overhang of the AC + rear overhang of the fan + about an inch of space between the two.
What dimension is the 8020? Looks about 50mm square so should be nice and rigid. Looks good by the way 👌
You don’t happen to have options for a 2018 Ford transit high top EXT do you?
It seems to me like there should be a splice kit that slides in the 80/20 about a foot long to increase the rigidity of the system.
It's plenty rigid as it is.
Thank u Guys Love the roof rack But i feel need a cover plate at the back as well where u can see the 80/20
Thanks for the suggestion. We left it open in the back to more easily allow air to flow through the rack and out the back. We will definitely look into some sort of cap though as we improve this product.
@@unakagearcompany Yes your right i didn't Think about the Air flow But a cap over the 80/20 where u can see the silver or maybe a bit of paint Thank u for your reply.Stay safe.
@@NSWMods The rack kits will come with end caps for the rear 8020. In the rush to get the MK1 installed we left those out and still actually need to send them to Nate so thanks for the reminder!
Ordered my Ford Transit Crew two weeks ago.Maybe ……..Mach 2023? I will be looking for roof rack !
Super cool! Exciting!
Any changes to GPS or FordPass app connectivity since the sharkfin antenna is covered?
Nothing noticeable. 👍
I would suspect a Dremel would work better to align the mounting holes in the roof.
Do you have a link to the outside electric step? I have a short wife and this would be perfect! 💯 My favorite Van build. Great video!
Thanks! Outside electric step? We don't have any steps on the van. You have a timestamp to share so I can see what you are talking about?
Exactly what I'm working on, designing 80/20 Transit roof rack to maximize area for solar panels. My guess is those large panels on your finished roof are 200w each, so including the small panels you are at about of 500w.
Yep! 580W more specifically. 2x200w, 2x55w, 2x35w.
Random question- what size is that window behind your driver side?? I’m assuming that’s an arctic tern? I think we ordered the same size and we hesitated to install it bc I read some threads that the larger flat windows can cause warping in the sheet metal, and it looks like yours does not! Any key to installing a flat window on a curved van?
I like it,, Been watching your vids you guys are doing a great job. I just finally got my new transit.
Waited 1.5 yr for it AWD I did the Weld Tec 2inch lift and this is the rack Im going with.
One question..Wher did you get the gasket for the front? Maybe save me some time if you have a link?
Prob simple Amazon search??
Thanks keep up the good work.. I will be shopping with you too..
Do you know if this roof rack will work on a mid roof? The suppliers website doesn’t list one for a mid roof.
Reach out to them and ask! They are super helpful.
Can you use a Dremel tool with a small carbide cutter to remove the extra tin that covered the tapped nut inserts in the roof? The hand snips leave a rough looking cut. - just my two cents
There's probably 100 different ways to do that. If you go the Dremel route, be sure to mind your sparks and such to prevent rust spots being thrown across the van roof. Remember... that part will never be seen, so a rough 'looking' cut doesn't really matter much.
Another idea is what I did which was use a multi-tool with a fine tooth metal blade. I prepped the area to contain the metal dust and this tool made fast clean work of it. In my opinion, this type of tool is a must for van builders. Really nice design on that roof rack guys!!!
Nice! Yeah, that's another good option. I do love my multi-tool. I was almost thinking that the 'upper half of a step bit' would be the ideal tool for that; but I don't think that exists and I didn't want to cut my step bit in half. 🤣😂
Looks like the fairing blocks the 360 degree camera.
Us not having a 360 degree camera also inhibits its performance.
The sealant you used, does it come out in a bread and then levels itself out as it cures?
Yep! It's 'self leveling', which means that after about 5-10 minutes, it spreads out into a flat seal: amzn.to/3zekmML
I bought the Flatline roof rack for my 130 inch wheelbase but mistakenly bought the 148 inch so now It wont fit. what can I do? Cut it down to size? I have 6 openings for the feet and of course they sent me 8. They don't even make one for 130 inch.
You're going to want to contact Flatline for their return/exchange policies.
Hey Nate, can you share how long you think it would take to set up this roof rack, minus all the tribulations? Oh how long you think it would take if you did it a second time?
I can't remember if I said how long it took to install in the video, but I think it was 4 days with testing different parts/methods plus filming? Maybe just go ahead and time-budget for that same amount of time to account for if you have different issues of your own? If we were to do it again with no prototyping or filming, it'd probably take 2 days with both the rack AND the solar panels.
No concerns with not having a welded rack?
Nope. Not a single concern, no.
What are the 3 different panels you used? Brand name and wattage?
Stay tuned! Thats the next video in the series.
Regarding the anti-cease; I noticed you used the gray colored. I have used the same product but switched to using only the copper colored. The reason I do not use gray at all for any reason is that it does dry and cake on the threads. Maybe not in a year or two but the coper doesn't and if so it would last years longer. Regard the two straps for bolting the side plate. I would recommend one big square with four holes, much stronger but maybe not needed if no cargo will be carried.
The installation process will be the same regardless of your preferred color of anti-seize.
One big square splice plate wouldn't work as it would get in the way of the 8020 rails. The small rectangular splice plates paired with the 'half-lapped' 8020 joint is plenty strong.
The copper anti-seize does stay soft. Use just enough to put a light coat on the start of the threads. As you run the bolt in, the the anti-seize will be pulled into the nut. You also have to be very careful to fully clean it from any exposed surface. If you get it on your hands, clothes, gloves, you will track it everywhere and keep doing so. It is the gift that keeps on giving.
😎❗️… just for the record, I still miss the “old page name” 😂 LoL
Adventure in a Backpack? 🤣😂 I sure don't miss typing all of that out or saying it in-person.
Could you link to the mk1 rack? It's not listed on Unaka's site.
We're working on the product/sales page and will have it available within the next few days. I'll circle back around here once it's available.
Hey Kevin! The link is now live. Here it is: unakagearco.com/collections/ford-transit/products/explorist-life-transit-roof-rack/?dt_id=105323
never used lap sealant......you should mention any tips on how much /far / thick to apply to get it to spread evenly /correctly.....or if it is no big deal splurge away. Seems like it could turn into a messy nightmare quickly.
It's definitely something I recommend practicing on a scrap piece of 'something', but going slow and letting it flow is the key. We talked about lap sealant in a bit more detail in this video, which may help: ua-cam.com/video/bOxl6IZvY2U/v-deo.html
@@EXPLORISTlife thanks, I've worked with other sealants and noticed your work turn out excellent in this vid and thought.....that takes a little skill and can turn ugly quick.
Great video guys, what's the sealant your using?
That's Dicor Lap Sealant: amzn.to/3J6QcQ8
I have unaka’s current fairing for my build where could I source that gasket from?
Unaka is going to have that available soon so you can buy 5-6ft of it, but until then; this is what we used: amzn.to/3zBPneU Pay special attention to the edge width. Our wind fairing is 3/16" so we used 3/16 edge gasket. 1/8" edge gasket would not fit.
@@EXPLORISTlife thanks I appreciate it!
Great information. Does the gasket on the front of the rack come when ordering the roof rack. Thanks Don
Thanks for watching! The gasket does indeed come with the roof rack. We really liked the concept of having the fairing come all the way down to the roof line, so we decided to include the gasket. After our maiden voyage from Steamboat Springs to McCall Idaho this weekend, we averaged 17MPG, which I'd like to think that the low fairing angle helped with.
@@EXPLORISTlife is there some place we can get that gasket? I have unaka’s current fairing and would like to get that gasket.
@@ryansparrow2554 We will be offering the gasket as an additional accessory on our website soon.
Unaka is going to have that available soon so you can buy 5-6ft of it, but until then; this is what we used: amzn.to/3zBPneU Pay special attention to the edge width. Our wind fairing is 3/16" so we used 3/16 edge gasket. 1/8" edge gasket would not fit.
I'm seeing a 404 error on the link?
Fixed.
Hi Nate, I have ordered the Rich 200 watt panels off you. Did you use the Unaka 59.265 cross bars on your roof rack? I am probably going to get AVC to adapt their roof rack for these solar panels as Unaka haven't responded to me for about a week. It's a Shame, their roof rack looks great and priced to sell.
You should absolutely follow up with Unaka. It's the holiday season and all of us small businesses are slammed. Sometimes I mean to respond to something and simply forget to hit send, and a quick and friendly 'Hey, Just following up on this', is very welcome.
@@EXPLORISTlife O.K I will do. They are a great price and offer the wider crossbars since you did your rack. Thanks. Brian
Hi Nate.
Nice rack!
Like the fairing gasket.
I like the way you’ve covered every inch. Not sure how much a/c and vent will shade panels but newer panels are not as sensitive to shading power reduction as they used to be, right?
How will you remove snow from your roof? No place to stand up there. Not that I would feel safe standing in snow and ice.
Planning to use Portable ladder or ?
There's only shading on one of the 35W panels when the sun is low in the sky (early morning and late evening); but is just one of the 'it is what it is' things of having a roof rack as low profile as this.
We will simply carry a portable ladder for snow removal. Even on our sprinter, it was sketchy to stand on the roof, in the snow, to remove the snow. Super slippery. With the portable ladder leaned on the roof rack, I'll only ever be, say, 4-5 ft off the ground in slippery conditions instead of 8+ feet of being on top of the van.
How much is the rack going for?
Here's the link to the sales page where you can check up-to-date pricing: unakagearco.com/collections/ford-transit/products/explorist-life-transit-roof-rack/?dt_id=105323
Please put même on the list
Here ya go! link for the rack is now live: The link for more info on our roof rack is now live: unakagearco.com/collections/ford-transit/products/explorist-life-transit-roof-rack/?dt_id=105323
Hello. Check an alternaive rail system MINITEC. It has M8 slot for standard nuts or spring loaded nut to keep it in position and many other features. It is available up to 6m lenngth which is less comlicated to screw together but more expensive in transport. UPS only takes max. 2m.
Maybe I'm just a bit jaded that we spent so much time developing this roof rack just for you to come in and suggest something totally different, but it also looks like minitec is difficult to actually purchase/acquire without having to jump through hoops (emailing/calling) for no real benefits.
So it sounds like if a Ford Transit owner wants to install a Nomadic A/C, Maxxair fan, maximum solar panels, and roof rack like yours, they should get all the measurements from you before cutting that first hole in their roof.
Absolutely. I gave all of the measurements for the A/C and Maxxair fan in our previous videos; but I strongly recommend anybody plan out the entire roof before cutting holes even if they aren't following this plan exactly.
One has to hope that the head of marketing at Loctite was subsequently fired for packaging its Blue 242 in a red colored squeeze tube.
Joke is on them as I'm colorblind. Makes no difference to me! 😂🤣🤷♂️
@@EXPLORISTlife LOL. You must really "appreciate" when an electronic component uses a single dual-color LED as a status indicator. "So, this means it's light-gray when fully charged and very-light-gray when charging."
Too bad stainless steel fasteners weren’t an option in the kit.
They are indeed stainless.
Probably easier building on the van
Probably not, but feel free to give it a shot if you think that's better. 🤷
@@EXPLORISTlife absolutely 👍🏼
A 1000 bucks for a roof rack smh
Hey there, big guy! I'm sorry you've got so much negativity going on in your life that you have to spend your time coming to my channel to talk shit on my projects. Maybe logging off of the internet for a bit and going for a walk or hanging out with friends if you have any may help. Thanks for watching anyway and I hope your day gets better. 🙂