How to install a MaxxFan into a Toyota Coaster. Steps below:
The MaxxFan deluxe has been a great addition to our build, if you are tossing up whether to install an exhaust fan or not, you must install one!
Helps you avoid mold problems later and helps move out stale air too.
How to install the MaxxFan Step By Step:
Step 1 - Choose where it's going
Things to consider is that it may be best placed near wet areas which can have steam. For example, the kitchen or bathroom.
Clean this area with acetone in preparation as you will be cutting next!
Step 2 - Build the frame for the exhaust fan in preparation
As Toyota Coasters and other vans have a very thin metal ceiling, it's important to reinforce the exhaust fan with a timber frame.
To create this frame, cut four pieces of 2x2 inch wood with measurements of 400mm X 400mm to make a wooden frame for exhaust fan. Glue the pieces together using sikaflex or a very strong glue or alternatively, screw them together, clamp the pieces together overnight to ensure they will stay in place.
Important: Drill a hole in preparation to run the wires through this frame later!
Step 3 - Measure, mark and prepare to cut the roof
Use a measuring tape and pencil, mark a 400mm X 400mm (The size of a MaxxFan Deluxe) square on the interior and exterior of the roof at the chosen location. Line with masking tape in preparation and redraw the lines to ensure you can clearly see them.
Drill four holes, one at each corner of the square. Use a small metal drill bit to drill pilot holes at each corner of the square. Now choose a drill bit which will fit your jigsaw cutter blade after. Screw bigger holes at each corner of the square, using the pilot holes you have just drilled.
Important: When you cut into the roof of your vehicle shards of metal will fly out. These shards can rust your vehicle. To avoid this, you can line the underneath of where you will be cutting the hole with a plastic bag.
Step 4 - Cut the hole
Using a jigsaw, cut out the square marked on the roof.
Step 5 - File down the cut metal and rust protect the area
Use a metal file plus fine sandpaper to smooth the edges of the cut-out hole on the roof. Clean the area around the cut-out hole inside and outside the van using isopropyl rubbing alcohol to remove any dirt and metal filings.
Apply rust protect primer and rust protect paint on the exposed metal around the cut-out hole to protect against future corrosion.
Step 6 - Waterproof and seal the exhaust fan rim and glue the timber frame
Apply strips of bitumen tape (Waterproofing tape) on all four sides around the cut-out hole on the roof to smooth out the surface and waterproof the area.
Apply a thin bead of Sikaflex sealant/adhesive to the inside of the Maxxair Maxxfan Deluxe plastic backing flange. Flip the plastic backing over and press it onto the hole in the roof, making sure it is evenly distanced from the edges. Press the frame onto the mastic/butyl tape seal and clamp it down for a few hours. Apply sealant around the edges of the mastic for extra waterproofing.
Apply Sikaflex adhesive to the inside of the wooden frame and clamp it to the roof of the van from the inside.
Step 7 - Screw down the rim of the exhaust fan into the timber frame.
Step 8 - Put the exhaust fan in
Place the body of the Maxxfan Deluxe into the plastic rim which is now attached to the roof and connect it using the four screws provided.
Attach the plastic trim to the inside part of the fan by fitting it into the frame with four screws beneath.
And that is it, overall we have been so pleased with our MaxxFan Deluxe. The remote control function is excellent, and it is so quiet, never disturbs the area for us. Good luck with your install, let us know how you go below in the comments!
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