This is what I started with, this hole was originally the air conditioner which was one of the first things tossed.
I obviously can't be trusted with a zoom!
I've read other blogs where they have completed this project in a couple of hours (while holding a beer in one hand no less!). That was not my experience. I spent almost 5 hours the first day just removing sealant, silicone and some type of martian spit, I guess. I used aluminum oxide abrasive wheels, brass brushes and such. Lots of plastic scrapers/razorblades and fingernails, did I mention fingernails? Mine look like they've been chewed on by a beaver.
I did it from the inside, perched on the top of a ladder for so long that my feet went numb and the next day I had a narrow bruise that ran all the way around my rib cage from the edges. THAT was my experience! And I had the good fortune to repeat it later in the week! Lucky, lucky me! Note to universe; I would just like one project on Moonraker to go easier than I think it will!
This is were I was after 5 hours and a good cleaning with acetone. You can see where I marked it for cutting. The hole needs to be a little bigger for the Fantastic fan. I just used aviation snips to cut it and then rounded the inside corners with a small round file. And hyperventilated while doing it! Nothing scarier than cutting into the skin!
I used Eternabond doublestick tape for the seal between the roof and fan. I then went around the whole perimeter with Tempro 635, this was because I was concerned the sharp edge of the flange would create a stress point. Then I used Eternabond tape (actually the 4 inch Alumibond, that has a shiny foil surface) on top of the flange and roof . I pre-drilled holes with a 1/8 inch bit for the screws.
I guess its the OCD in me but in my mind this makes for a much cleaner looking installation and no little piles of white doggie poo (aka Tempro) on the roof of my Airstream. It will also be much easier to inspect for leaks, and if it starts to lift I can repair it.
I did the two installations slightly differently.
The middle one I used 1 inch #8 SS pan head screws and washers like recommended by Colin Hyde. Unfortunately, that made it harder to use the roller to get the Eternabond tape down. Kinda key because pressure is what activates the glue in Eternabond. On the rear installation I used stainless steel machine screws this left a smooth surface on the flange of the fantastic fan that was much easier to roll. I'll check back and tell you what works better!
There was no rain in the forecast but immediately after I installed the first one with just the doublestick and screws, it POURED, and kept pouring. I was amazed that even without the Trempro and Alumibond tape that the installation was leak free! I'm hoping these will remain leakfree for many years to come!
A couple of notes if you haven't installed yours yet, make sure you do a dry fit to see if the Fantastic lays flat on the roof. I doubled up on the doublestick tape in the one area because the roof starts to slope down by the end cap. I had a much bigger gap in the back than the front. In retrospect, I wish I had trebled it. I ended up using a rope of the doublestick to fill in the gap.
Also, on the second go around, I drilled out the original fan housing , pried it off the roof, then I painted on Citrastrip, covered it in plastic and left it overnight. It turned a five hour job into a two hour job. Got up the martian spit nicely! Of course nothing really touches the silicone, but I think it even helped there. So if you have the time to let Citrastrip do its job I highly recommend it!
I used acetone to clean the roof really well before I taped it. Don't get it anywhere near the fantastic fan though because it will dissolve the plastic (ask me how I know....) Use mineral spirits for cleanup instead!
Finished Installation. :)
And look what arrived in the mail! Just in time to plug the other large hole in the roof! Any guesses?
