DIY Portable Roof Fan – Minivan Camper Essential

Are you looking to beat the heat during your minivan camping adventures without breaking the bank or permanently altering your vehicle? You’re in luck! In this blog post, we’ll guide you through the process of creating a DIY portable roof fan for your minivan camper. This project is simple, cost-effective, and doesn’t require any complex electrical work or permanent modifications to your vehicle. Let’s get started!

Materials You’ll Need:

1. 1/8-inch thick Masonite hardboard (or similar thin material)
2. 7-inch diameter USB rechargeable desk fan
3. Reflectix insulation
4. Basic tools like Jig saw, a drill, and a screwdriver

Step 1: Fan Selection

Before you begin, it’s essential to choose the right fan for your DIY roof fan project. Here are some tips to keep in mind when selecting a fan:

• Look for a rechargeable fan between 6 to 8 inches in size.
• Smaller fans tend to have lower suction power, so aim for a balance.
• Ensure that the fan can be disassembled by loosening the screws.
• Check that the battery and motor are housed together in the fan unit.
• Having a remote control can be quite handy for convenience.

Step 2: Creating the Panel

To create the fan panel, you’ll need an 1/8-inch thick Masonite hardboard or a similar thin material. Follow these steps:

1. Create a template using cardboard, or in my case I reuse an existing template since I’ve made an insect screen last year for the moonroof.
2. Cut the panel to match the template, trimming the front corners to fit closely with the frame.
3. Cut a 6 – 3/4 inch opening in the panel to accommodate the fan unit.
4. Secure the fan unit to the panel using screws. Be sure to predrill small pilot holes to prevent cracking.

Step 3: Insulate the Panel

Since the backside of the panel is exposed to the sun, it can get hot and potentially cause the panel to expand and warp. To counteract this, insulate the panel with reflectix:

1. Use spray glue to adhere reflectix to the panel, leaving a 1/2 inch recess on the rear and 1 and a half inches on the left and right sides to clear the track and sunshade.

Step 4: Installation

Now, your panel is ready to be installed. Here’s how to do it:

1. Align and insert the driver’s side of the panel into the track first.
2. Gently pull down the middle portion and slightly bend the panel to fit through the opening. It should slide right into the tracks with a bit of space for expansion.
3. Close the sunshade and open the moonroof slightly for optimal airflow.
4. Turn on the fan, and if possible, crack open the rear vent for efficient airflow through the cabin.

Step 5: Optional Fan Cover

Consider creating a cardboard cover to protect the fan blades when you don’t need the fan. This cover can be easily stored when not in use.

And there you have it—a DIY portable roof fan for your minivan camper! This uncomplicated project is not only budget-friendly but also allows for easy removal and installation. Enjoy the cool breeze during your camping adventures without any hassle.

If you have any questions or need more details about specific parts or the installation process, please feel free to leave them in the comments below. Additionally, if you find the right fan for this project, don’t hesitate to share the links with the community. Happy camping!