DIY Aluminium Roof Rack NO WELDING Ford Transit Conversion

Ford Transit Van Build Australia | Vanlife Australia Episode 2

We now have a website where you can access all our van 3D models (including the roof rack and ladder designs), diagrams and complete cost breakdowns as well as Van Build Consulting
Visit our Website https://saltyvanventures.com

▬ 3D Models https://tinyurl.com/yckurw7e
▬ Cost Breakdown https://tinyurl.com/y8kkh6cr
▬ Electrical Diagram https://tinyurl.com/mrxt3r9h

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This is the second build episode of the series where I build a CUSTOM ALUMINIUM ROOF RACK for the van for under $300. The greatest part about this is that it requires NO WELDING . I Still may decide to weld it together later as I do have access to a welder but from a proof of concept point of view it performs really well just pop riveted together.

Ford transit van build episode 1 ►    • FLOOR INSULATION (and sub floor) New ...  
Chile Van Build ►    • Vanlife South America  
NZ Van Tour here ►   • VAN TOUR | DIY Stunning Converted TOY...  

Aluminum Cut list
Side rails mounted to the roof:
40mm x 40mm x 3mm square (3250m long) 2 pieces
Frame side members:
50mm x 25mm x 3mm (3250mm long) 2 pieces
Frame cross members:
32mm x 32mm x 3mm (1625mm) 8 pieces
90 Degree brackets to join framework together:
40mm x 40mm x 3mm (cut into 32mm wide pieces) 28 total
90 Degree brackets to attach roof rack to frame side members:
32mm x 50mm x 1.6mm (cut into 40mm wide pieces to) 16 total

PARTS USED
Here is the list of parts and items we have used on the van build is this episode and thus far. Some are affiliate links from amazon and others are where I could find it cheaper on other web sites such as Ebay. These are affiliate links for which I may be compensated if you purchase from the link.

THIS BUILD EPISODE

12v Exhaust Vent and fan https://amzn.to/3JJ7QsY
Hard plastic shims: https://tinyurl.com/y5pollc4

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FROM THE REST OF THE BUILD

Electrical
Circuit breaker https://amzn.to/3ah2iWz
2000w Pure Sine Wave inverter https://amzn.to/2P231Dr
DCDC 50amp charger https://amzn.to/3vS6B3x
Battery Monitor https://amzn.to/3cbsfrR
Circuit breaker https://amzn.to/3ah2iWz
Double Pole GPO outlet https://ebay.us/PsH4Jf
12v Switch Panel https://amzn.to/31r1z3M
Isolator switch https://amzn.to/3v01Vr9
70 Amp Fuse https://amzn.to/32TOLnb
135Ah Lithium Battery https://ebay.us/jPiXow
Blade fuse box https://amzn.to/3xgz1Fo
Wire connector kit https://amzn.to/3EYDnU9
100m wire roll 12AWG https://ebay.us/VOijcB
Split loom wire protector https://amzn.to/3nUtbal
30Amp relay https://amzn.to/3tHIlQ8
In line fuse holder https://amzn.to/3syyISC
12v LED downlights https://amzn.to/3lH7NCh
Dc-Dc 12v To 5v convertor https://amzn.to/3yOtxRB
12v USB charging port https://amzn.to/3G0sQsR

Solar Setup
100w solar panel https://ebay.us/N3rl0G
Large panel solar panels https://ebay.us/sWUKuw
Solar Cable Entry Housing Mount https://amzn.to/2QrvliZ
Solar Inline fuse https://amzn.to/2SZB15t
Solar Cable Extension https://amzn.to/3gZFPQj

Water System
85L Freshwater tank https://bit.ly/3locE9W
43L Grey water tank https://ebay.us/BgNneX
Water filler port https://amzn.to/2Q29jDz
12V water pump https://amzn.to/3lDV0Rd
Gas hot water heater https://ebay.us/XbUpHq
Water level gauge https://ebay.us/2QFPmN
Toilet https://ebay.us/eeG6wD

Kitchen Unit
65L Fridge https://ebay.us/gPZTbs
3 Burner Stove and Oven https://ebay.us/mk1Xnb
Kitchen Drawer slides https://amzn.to/2RkdOJW
Draw Handles https://amzn.to/2QOPTT9
Kitchen Mixer Tap https://amzn.to/3zwxnPR
Sink https://amzn.to/3ePVKQ2

Insulation
Foil Board Insulation https://tinyurl.com/28sjp9b8
Sound Deadener https://ebay.us/FJxrxG
Polyester Insulation https://tinyurl.com/ybcnp8zs

Windows
Pop out window https://www.tinyurl.com/18izsan5
Sliding window https://www.tinyurl.com/8xudhdfb

Handy Tools
Rivnut Set https://amzn.to/3u92wqy
Contour Gauge https://amzn.to/3eaIbvj
Gas Soldering Iron https://amzn.to/2PGQkOK
Kreg Pocket hole jig https://amzn.to/3xUEcKA
Stainless Wire Brush https://ebay.us/UGNEg3
Brazing Rods https://ebay.us/rTSkSD
Mapp Gas Torch https://amzn.to/3xHEKDi
Silicone Finishing Gauges https://amzn.to/3sC8U9N
Sausage Gun https://amzn.to/2XAG9z5
Notched Trowel https://amzn.to/3nWgvja

Ventilation
Sirroco II fan https://amzn.to/3nIZt7r

Roof Top Deck
Led light bar https://ebay.us/fKrS9Z
Tie Down D rings https://amzn.to/3nFHy1q
End caps https://amzn.to/3wNTEYk