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Old 03-29-2011, 07:46 PM   #1
Graphite Dave
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Default Orton DIY - Maxxair Fan Install

I chose the Maxxair 6200K fan for two reasons. It was designed so it can be open while driving and it can be open in the rain. I did several things that I thought would improve the installation. I made a 3/4" plywood backing plate picture frame to install inside to reinforce the opening and I made 1/8" x 1" aluminum plates to distribute the load at the bolt heads. The RV places said the plastic frame will crack at the bolt holes so I added the aluminum strips. I also did not want to use the SS sheet metal screws supplied and instead used through bolts with an elastic stop nut.

Procedure:
1. Made a 14" x 14" plywood template with a 5/16" hole in the center and four 1/8" holes in the four corners. The 1/8" holes were 7/16" in from edge of pattern. I used a 7/8" dia. electrical knockout to get nice rounded corners in the 14" hole.
2. Drilled a 1/8" hole through the roof where I wanted center of opening. Enlarged that to 5/16". Bolted plywood template to the roof. Rotated template as required to make opening square with the Sprinter cross ribs. Tightened center bolt. Used duct tape to hold template in place.
3. Drilled four 1/8" holes in corners using template holes as guide. Removed template.
4. Enlarged four corner holes in roof to 3/8" for knockout stud. Punched the four corner holes.
5. Drew a line tangent to 7/8" dia. holes to mark saw path. Cut between each corner hole with jigsaw from inside the van. Wish I had some clear goggles to keep metal out of my eyes.
Cut 3 sides of opening and then added duct tape on top and under roof on the three cut sides to keep 14" sq. plate from falling when I made the last cut. Removed any Mercedes sound deadening material that was in the way.
6. Put plastic fan ring into opening and held it centered with duct tape.
7. Went back on top and drilled the four corner bolt holes. Bolted ring down at the four corners. Drilled remaining holes by using the plastic holes in the ring as a guide.
8. Removed ring and cleaned up and painted edges.
9. Added butyl tape under flange and added aluminum strips over plastic flanges. So sandwich was 1/8" alum.,plastic fan flange,Sprinter roof, 3/4" plywood backing plate.
10. Trimmed off extruded butyl tape that was pushed out and then caulked the edges and the top of the bolt heads.
Attached Images
File Type: jpg 100_0630.JPG (136.9 KB, 4345 views)
File Type: jpg 100_0631.JPG (66.8 KB, 3957 views)
File Type: jpg 100_0632.JPG (186.5 KB, 3976 views)
File Type: jpg 100_0634.JPG (71.0 KB, 4098 views)
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Old 03-29-2011, 09:54 PM   #2
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Default Re: Orton DIY - Maxxair Fan Install

Hi Dave,

Excellent rightup.
I have the same fan but have yet to receive the van! Maybe it will arrive soon. I will copy your install and use the extra alloy plates too. Do you intend to paint the alloy plates?

Cheers

Ross
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Old 03-29-2011, 11:58 PM   #3
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Default Re: Orton DIY - Maxxair Fan Install

Will not paint the anodized aluminum. I have had anodized 80/20 on the bed flanges of my 2003 Dodge Dakota for 8 years and they look fine. If you bought a 144" WB van the magic number from centerline of second rib from back is 10 1/2" (centerline of second rib to centeline of 14" opening). The plywood frame will be against the flange of the second rib from the back and plastic fan ring will just miss center corrugation toward back. Attached is a PDF drawing of what I did. Should make it easy for you.
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Old 03-30-2011, 06:20 AM   #4
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Default Re: Orton DIY - Maxxair Fan Install

Ok thanks for the info. I did not realize that the flanges were anodized. That should be fine. Mine is an extra long (170) but I can still use the information. Gee I wish I had your cad package.

Cheers

Ross
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Old 03-30-2011, 03:55 PM   #5
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Default Re: Orton DIY - Maxxair Fan Install

Cad package: go to generalcadd.com and download free software so you can try it out. Free trial package is complete except you can not save drawings. If you like it buy it for $599.00. Nice easy to use program that is less costly and much easier to use than Autocad.
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Old 12-10-2011, 12:34 PM   #6
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Default Re: Orton DIY - Maxxair Fan Install

thanks for this Dave

I'm hoping to get a chance to install mine tomorrow.
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Old 03-31-2012, 10:02 PM   #7
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Default Re: Orton DIY - Maxxair Fan Install

Dave,
Thanks for all your write ups, they have been very helpful. I have a question...
I have a 170wb and wanted to put my fan toward the back where it would be over the bed, however that would require me to cut thru one of the ribs in the roof. When you did your install you had to flatten one of your ribs, right? Is this a bad idea to mount it here? How did you flatten your rib out? I was thinking of using a vice up there and squeezing it down. Thoughts?
Thanks. Matt
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Old 04-25-2014, 01:44 AM   #8
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Default Re: Orton DIY - Maxxair Fan Install

After thinking about it when power is restored vent closes. So if your intention is to turn the fan back on it is kind of the same issue.

Last edited by pfflyer; 04-25-2014 at 01:26 PM.
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Old 04-25-2014, 04:38 AM   #9
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Default Re: Orton DIY - Maxxair Fan Install

I sent an e-mail to Maxxair asking if there is a way to decouple on/off fan switch from lid lift drive. I can understand that coupling for switching fan on could be useful but not necessary.

Have I known that I would follow Dave's lead with fully manual lid opening.

George.

Last edited by GeorgeRa; 04-25-2014 at 05:55 AM. Reason: correction
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Old 04-25-2014, 04:07 PM   #10
Graphite Dave
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Default Re: Orton DIY - Maxxair Fan Install

Look at someones manual operated lid. Why can't you just buy the manual operated parts and disconnect the powered lid opening stuff.

I did not buy the remote because I know I would have lost it or dropped it. I try to have things as simple as possible for my feeble brain. Locating the manual opening knob and on/off switch within arms reach from bed platform has worked well. With the floor opening vent to get air flow, I have only turned on the fan about 10 times in several years. Open it regularly.
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