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By the way,  I recently created an update video on my build, Ep 14 - Update on Working with Aluminum on my Van Build.   I note this mainly because I pay some solid respect to maki2, and I wanted her to know it.  I know that many of you in the community don't have enough bandwidth to while away...

Maybe you can attach a pic of what you're talking about?  I don't think I've ever seen a van like that, and if it's what I think you're saying, I don't think I would have room for all my equipment on the roof by doing it.

Sometimes, things work out - at least I hope. The attached images give a better representation of the roof rack and the Maxxfan.  The photograph is the actual fan as unpacked from the factory.  Note that they thoughtfully include a "Garnish ring" which is about six inches long and is intended...

You may be right, but 1/8" just seems pretty weak for a roof assembly.  I do have a lot of supports, so maybe it would be okay.   I've pretty much given up on the idea of bending 1/4".  I'll use straight flats connected with brackets made of short pieces of L channel.  The pieces I'm talking...

Yeah, I've looked at a half dozen or so videos, plus web sites and online bend allowance calculators.  They all get to the point of putting the piece in a brake, and then assume you know all about brakes and how they work and their settings etc.  In my case, for lack of knowledge, I would have...

Good idea!  I was going to watch it closely to see the temperature variations.  You've sensitized me to the need to thermally isolate the hinged rack from the stationary rack to cut down on some conductive heat transfer.  One interesting possibility might be to modify the Maxxair fan to divert...

Hmmm ... maybe leave off the foam board on the side facing the metal wrap-around and let the wrap-around heat radiate into the pipe.

I will definitely think more about some enhanced air flow, but without catching the wind when I drive lifting the whole assembly off the roof.

So here are some thoughts ...  First, the tubes will be surrounded on three sides with foam board insulation.   More importantly, in the attached drawing, I've added some mesh screen, in red.  One is nearly horizontal on the front spoiler, and the other is vertical at the back of the panel...

I have thought of that.  My plan is to cut the painted CPVC into sections separated by plastic disks that have holes in the top and the bottom of the round disks and are inserted into the couplings.  That way, I can reduce the slosh to a 1 1/2 or 2 foot section.  I calculate the total volume for...

Great!  Love to hear more.  Got any pix or plans?  Are you enclosing the trailer?  How are you mounting everything? What are the hot water details?  That sounds like a neat "portable power station".

Yes, that's why the panel frame is open on the end pointing up. That way, I can extract it and tether it 20 or 30 feet away.  When the panel is "closed" - no tilt, the panel is secure.   The enclosure prevents wind from getting underneath to lift the panel, while providing  "hot" storage under...

Currently, I have some pretty ambitious plans for my van roof.  See the photos below.  The first is the ultimate goal, with fan, removable solar panel, tilting panel, water tubes, and not-weather-proof storage under the panel - all wrapped with an enclosure to keep the wind from lifting...

  The attached images are what I'm working with.  I've done a pretty detailed cost estimate of the aluminum.  It comes to about $200 for these three pieces.

So maki2, I'm discovering there are lots of different kinds of sizes, types, and suppliers of rivets. What are your recommendations? Anything to be aware of to ensure the strength, tightness, and durability of a rivet connection?

Correction on this ...  5052 is aluminum sheeting.  The same flexible alloy in a 1" x 1/8" flat is 6063.  Most aluminum flats are the brittle 6061 and, from my local supplier, cost $9 for a 12 foot piece.

How to make a coroplast container. This gives the basic idea, and I'm sure there are many ways to improve it to make it stronger. One key concept in the video is that you bring the sides of the box up and attach one flap to another using screws screwed through one flap and into the natural...

I think using plastic boxes is a great idea if you can find the right size and shape.  For my little van, I don't think that's going to be possible, so I have an alternate idea. Y'all who think building with aluminum is crazy might think this is a crazy idea too, but here goes ... I'm...

Very cool!  I look forward to hearing about all your building choices.  Give us an idea of your initial thoughts?  What are your goals for the build?

Found a couple videos that go into some detail: If you only have 6061, use heat to bend it. Otherwise, it will break.  See this video. If you can find 5052, you won't need heat to bend it.  See this video. Good points about the square channel.  I'll change my design for the bed.  Btw, I just...