The components on the roof are the minimum required, with none being unneeded. As illustrated, they add up to be more than 70 lbs over the manufacturer's rating. This will be an ongoing issue with the Ford Transit as a platform for building. I will add additional structural support to compensate for this shortcoming.
thanks for taking the time on all the videos George. was going to ask about the 73 lb's overweight. makes me wonder if other convertors are reinforcing the Transit roof ? guessing not.
I've seen that Flatline also offers a "safari" roof rack that has a deck. I was originally leaning toward that, but after watching your video I'm wondering if the transits roof is flimsy enough that the safari version of the deck would be a bad idea? Or perhaps the weight is distributed evenly enough that it would be ok?
RV's badly need an alternative AC/heatpump system that is affordable and not roof mounted. Could use a compact mini-split type or window type that deploys thru a side hatch. I believe I saw a motorhome with an LG split system integrated in the sidewall. Better yet would be making use of the vehicles AC if it had an electric compressor. Tesla's allows similar capability for their dog mode. Personally for boondocking or full-time use, I would minimize the roof holes and maximize area for solar. I would only consider one opening for a marine hatch for stargazing, roof access or lookout. I can think of viable alternates to roof fans. I like the idea of tilting or sliding solar panels to uncover the hatch and roof deck. Sliding panels side or rear could act as a mini awning.
@@coopcraige this is the first Transit roof reinforcement I’ve seen beyond what George already does with wood supports to accept the screws for fan/AC installs. By the BEMM, seems like a structurally sound method (he did a pull-up for goodness sake!). It totally blows my brain on how I started designing my ceiling panels though 🤣 back to the drawing board if I decide I need angle aluminum. I’m planning on a maxxair in bay 2 (bay 1 is the curved bay) and was leaning to the Dometic RTX 2000 in the rear most bay with Hein’s DIYVan adapter. Maybe with that layout I don’t need those angle supports… maybe. I need to research that more.
@@YT-MY Yup, an easier and cheaper AC unit, window mounted, could be this Eurom 2401. Also, what van people DO NOT understand when mounting solar panels on the roof, be it secured flat or rolling some to catch that sun, is that most of the time they’ll need to park under a tree for shade. Otherwise in the summer sun the exposed surfaces are huge, to the point that any AC would not be efficient! Therefore, it would be best to have some sort of mobile/tilting/side mounted solar panels that could either follow the sun by adjusting the angle or even move to opposite van sides. Leave the van under the sun in the summer to produce electricity that is spent to cool that van down again, seems absurd in my mediterranean eyes...
Hey George, we share a little bit in common in that I'm a graduate from Brooks Institute. Advertising /Illustration photography and color technology. Nice that you take the time to set up the lighting for these shoots, and even explain to the public. The attention to detail is admirable. Well done sir!
Great work preparation. It's like a surgeon! All tools and instruments needed for the operation are neatly organized within reach. I can see the pro photographer is still there in the van builder / TH-camr with the lighting technique.
The DaVinci of Van Builds. Bravissimo Maestro! Such craftsmanship is rare today. This was a treat to watch, including the photo tips. This is the zen of van builds.
I bought a roof rack from Flatline just a couple weeks ago after first considering 8020 and unistrut options. The weight was really the deciding factor for me. They are expensive, but the time and weight saved was nice. It was also already in stock and arrived in 2 days. I was expecting they'd have to be cut to order, so that was a nice surprise to have it so quickly.
I have not encountered a third-party roof rack that’s wide enough to accommodate solar panels, air, conditioners, and fans. I still prefer to build my own racks out of 10 series 8020.
@@HumbleRoad I don't plan on adding an air conditioner, but the rack (extended roof model) easily supports 800 watts of panels, MaxAir, weboost, weather station, and starlink port. The cross members can be placed wherever you decide, allowing for highly customized configurations. It's possible the design has evolved. Nonetheless, I respect your preference of using 8020.
@@NomadicPride sorry what I meant to say is when there’s an air conditioner mounted in the center of the roof. There’s no room on either side for solar panels flanking the air conditioner. I had to cut the flat line rack and spread it and add inserts to the crossbars in order to fit my solar panels. It worked just fine on two Ford transit but I don’t wanna do that every time. Now, I’m going with the Orion roof rack on 24 transits. I’ll let you know how that goes.
@@HumbleRoad Thanks for the clarification! I wasn't totally getting it, but knowing the air conditioner is center-mounted brings it clear. While I'm in for the FVC rack now, I'd still love to hear how the Orion does.
thanks for showing the setup for filming. many people fail to realize it takes twice if not three times as long, to document your stuff as it does to plan it out and successfully complete the task itself. --great quality-- happy new year and continued wellness.
In the not too distant future, you will see a lot more awnings designed to also have mosquito netting all around. That is a design challenge, but a real necessity in so many areas in the summer.
Thanks for the lighting detail. I remember you saying you were a photographer in your previous life. I think you said you did commercial work??? I owned a Portrait Studio for 17 years (Families, babies & High School Seniors). Great lighting often, and should, goes unnoticed. Poor lighting is always noticed. Your attention to detail is very much appreciated.
You say flat lining is the last thing you want to do and ironically it exactly the last thing you will do someday. Hopefully not anytime soon cuz I love your videos and soaking up your wisdom.
You have supreme taste in style and design. I searched 12 years for a roof rack and when I spied one in the Pearl I buttonholed the owner to know the producer (FVC), local, a few miles away. Their business model is trim and efficient but their customer service is sterile like so many today. Their products aren't as good as you would produce but I've not found better in the last two years. My years in metal trades makes me think Flat Line refers to a positively square angle. IOW, damn straight.
Since when do van vids provoke hilarity along with a valuable educational experience? Since Humble Road of course :-) Thank you George for the insight and the laughs and the overall impeccable quality! Flatliner out.
Ha! If I set my mind to it, I could most likely become a good cook. At this point in my life, it doesn't interest me to the point of doing the "deep dive" as we say these days...
Per the BEMM all of the roofs are rated to the same 420lbs, the owners manual derates the high roof to only 220lbs based on the center of gravity of the factory configuration. Ford expects upfitters to do their own center of gravity calculations based on the formulas in the BEMM and adjust the available roof capacity based on those.
Harmonics are important. Wind-induced harmonics brought down the original Tacoma Narrows Bridge for which there is film footage. I think about vertical springs on top of the roof and under the frame with round rubber feet at both ends.
You're too much... I love it! Thanks for the recommendation on the Transit rack. Planning my build right now so compiling my list/resources of must haves, and this is definitely one! 👍
So thanks 4 the break down on the lighting set up n camer angles, n your general due diligance the thing 2 consider re rain is angle of rest of the van it may not alway park so it maintains perfect flatness alao what was happening in the past is no where indicitave of whats poszible now expecy much more erattic weather things like massive hail dumps followed by 2 inches of rain in minutes become fairly common
I'm seeing rubber hockey pucks being used as cushions in roof rack systems. I'd like to know your thoughts. They also used silicone on body under puck.
I didn’t know there was a proper orientation either. But why does the polished side face the nut? Shouldn’t the polished side face out? Or is it polished to show the user this is the side that needs to face the nut? Thanks
Hey great info. I see Flatline has some stuff on sale right now. Very reasonable prices. Thanks George. High thumbs up on the production insight at the end!
Good to see you work with so much care and finesse George. Not kidding with the tin construction of the Transit. I had to build a surveillance vehicle on a high roof. Had to install a 15m pneumatic mast in it which was huge and very difficult to stabilize in the vehicle structure. Even the crew/operators compartment was a nightmare as rivnuts don't hold well in the flimsy inner frame. I have also noticed that corrosion on the underside is a potential issue. The van has now done around 30k and only has light use as well. Maybe the US ones are better than the UK vans? Keep up the good work.
No one can say enough about your precision, skills, organization, and self-marketing. You're the best George. My inspiration and (difficult to reach) benchmark for my DIY Sprinter Motorhome. Thanks for sharing.
How much weight savings is there compared to 80/20 as the backbones? Have you used 1.5"x3" (40/80series), run upright for backbones? You have really good & helpful data in your videos.
Thank you for another great episode. Not only do I enjoy the content and your meticulousness of your builds but also the care with your video production. BTW, you should do a few lightning tutorial videos for youtubers. But mostly I enjoy something intangible of your personality and humor. I get in good mood watching every one of your documentaries. This is top notch!! Thank you.
You just keep on giving and instructing ... custom vans and ... as well as now - videography! Thanks you, for all you do, and most of all, all that you share.
Great minds strike again! I too settled on FVC for my roof rack; waiting to see what their new model coming at the end of January brings to the table. Pretty sure those bolts from mounting bracket into the van holes are M8.😉 Great vid both informative and entertaining as always, George!
Great to see your pro photog tips and the fact that you spend a great deal of time in the production side of your videos (unlike most all utubers). Being from the south where its hot most of the year, air cooling is something that is necessary. I'm surprised you haven't switched to something more efficient than those noisy watt hogs that most RVs use. A good high-SEER (120v or 12v) mini-split uses about half the power, is far quieter, and also provides heat when needed. Additionally, they don't add height and top heavy weight to an already tall vehicle. On the other hand, they do require something you love to do - solving the problem of where the 2 main components are installed! Keep up the good work and be careful on the scaffolding - perhaps a safety rail around 3 sides would add a layer of insurance for you and your employees.
Hey George! Thank you for enlightening us! And for other tips and advice. Maybe I'm just going to rent one room just to put some things together. And maybe put my snow-covered pickup truck in there too.
Your technical thoroughness is amazing... you make shortcut a 4-letter word! I’ve been looking at manufactured and diy used vans for a little while, but your videos have set a standard that makes it hard to settle for less.. Thanks for the masterclass!!
Now I feel like my FVCO rack choice has been blessed by the pope! I added the front FVCO faring option to break the wind on my front roof fan. And it looks cooler than a bar. 😉 I so appreciate the time you put into posting videos when you are so busy managing your van build family. Quite admirable, especially with the care spent your professional lighting. I have yet to start editing my van build footage. I’m slow enough as it is! But I love the puzzling process. I look forward to showing it to you when I finish it - probably around 2025😝 It has been the Perfect Pandemic Project.
Big thanks for the 'behind the scenes' segment! Would love to see more of those, also involved on the shop side. I'm vey curious how you have material storage in the shop for wood and aluminum, both sheet and stick product.
Just to quench your thirst; I don't bulk purchase materials. ALL material is ordered/purchased per van, for that van. I don't inventory anything! Great for cashflow! So, as I receive it, we build it and install it.
@Humble Road Thank you so much for sharing your lighting setup. Are the lights fluorescents? I enjoy your content so much, and the BTS is the icing on the cupcake.
I just asked a question on your video: “Custom Van Build - FORD TRANSIT - High Roof Rack, Weight Issues and Fan Leveling Gaskets.” I thought this might help for your time and troubles. Thank you!
1) 0:43 TOTAL WEIGHT LIMIT HIGH ROOF EXTENDED CHASIS: Transit 220 lbs, Promaster: 330 lbs, Sprinter: 330 lbs. 2) 0:47 Fiamma 45S 10’ awning = 49 lbs. 100 watt solar panels = 57 lbs. 3) 0:55 Flatline Van Company roof rack = 65 lbs (which is lighter than a custom 80/20 rack because the Flatline rails are lighter than 80/20 rails. Flatline roof rack will use 80/20 crossbars.) This rack is pre-made to accommodate the Fiamma awning and solar panels. 4) 1:27 Rack 65 lbs + Awning 49 lbs + 4 100 watt solar panels 57 lbs + 2 Maxair fans 40 lbs + AC 82 lbs = 293 lbs. 5) 1:42 Installation of Flatline roof rack on For Transit begins…
Another informative video. Hey George, since I have been a fan “from the beginning,” I know your first career was as a profession (top in his field) photographer. That is why your videos look like you hired a videographer when all time you are both the guy behind the camera and the guy in front of the camera!
George, I'm enjoying your Transit conversion. I started my 2020 Transit conversion a year ago, the Flatline roof rack was my first installation. I've come across one challenge ... the bolts that connect the 80/20 1010 rails are frozen ... at least one of them is, it's been stripped out, and I haven't found a way to get it out. It's the only failing part of the FlatlineCo roof rack for me.
Fantastic video and nice product. My feeling is weight is everything, like a serious backpacker or bicyclist. Quality and lightweight do not have to be opposites. My thinking is why carry excess weight, it stresses the vehicle, can degrade vehicle safety and limits what necessities you can carry. Is that bare metal exposed around the roof holes? I would paint any bare metal to limit future rust. It would be interesting to measure the thickness of the different van roofs. Looks like the Ford has greater flat area down the center for better opening/mounting options.
Nice vid George 💯...now I wonder if all the others that mount waaaay over 220 pounds up top have reinforced their setup at all....or just "wingin it"...???
Roof weight limits are the dirty little secret of van building. I see many vans waaaay overweight up there. And the 220 lb limit on the Transit is a big problem!
George that is a nice rack. I've seen videos of vans with walkable solar panels. It's called a deck. I believe they are on a Sprinter. With one person it would be too much weight. Looks like you will be over weight on the Transit van.
Nice-nuts, I didn't know! So there's a gap between the bottom of the roof panel and the start of the "plus nut" threads? If water were to get past the silicone and the foam pad, wouldn't it leak into that void? Where is that void inside the van, in a roof rib or support strut? If that's the case, does that water drain out through a weep hole or into the insulation? My free advise, worth exactly that, is caulk the whole perimeter of the AC: Wind driven rain and the occasional high pressure wash will force water uphill.
Oh make no mistake! The entire gasket is glued and sealed all around. And that's where you could stop, particularly with 3M5200 or 3M4000, you should never have a problem. But I go a step further, and you are correct, that driving rain is very smart! It can find it's way into the slightest of voids!
But to answer your question, The holes are located so far outboard that any leak would run down the wall down into the weep canal under the floor. But I will not allow that to happen!
QUESTION: I have a 2023 Ford Transit Trail. It comes stock with the MaxxAir Fan between the front two support ribs. I wanted to put an A/C unit in the middle section of ribs (which happen to be the farthest spaced), and you mentioned fabricating some supports for the weight of your A/C unit. Would you share what your solution is to this issue? Thank you! Truly enjoy your videos!
I went a little overboard with my solution to spread the load across the ceiling. Additionally, I incorporated it into a design move, running a boardwalk, all the way down the center of the ceiling see the video. Custom Van Build - FORD TRANSIT - Air Conditioner? Xtra support rails are a MUST-HAVE in these vans! th-cam.com/video/LoxWc12vcGc/w-d-xo.html
Thanks! I miss that suite, I spent hours and hours in there, very cozy. That was an old clip and I have since given that space over to my son, Andrew. He turned it into a bicycle mechanic's room. He's a bicycle racer.
OK, right now I'm in the process of putting together a control console to improve my editing skills. I'm dedicated to taking my videos up a notch in both content and quality this year.
Now that you have some experience with both your own 80/20 and this flatline branded rack, I am curious about your thoughts on using a plate rail vs an extrusion for the outside rails. Plusses and minuses...prefferences...
You know you threw me into a tailspin! The 220 lb weight limit on the roof isn't about the walls crumpling or any of that - it has far more to do with how top-heavy the van can be on the road without tipping over on corners! I started planning on fortifying the ribs and got way into it until the coin dropped and I realized - this isn't its structural limit it is its _practical_ limit. You did say near the beginning "perhaps because of how tall it is" and that is totally what it is.
How's your build going? I'm debating a similar notion - as I plan to make the van's center of gravity lower (for driving), but for static situations, I want to have the roof rack, solar, and a possible deck we might even be able to stand on. =)
George, would it be an option to use brackets on just one side for the awning and utilize plastic, glue-down mounts for the solar panels (assuming you have the roof real estate)? This would eliminate the crossbars and at least one side of the rack. I’m also working to reduce weight as much as possible. Trying to avoid a roof rack entirely. Always a pleasure to watch your videos!
I prefer a "wall mounted" awning rather than the "roof mounted" variety. And I like to keep plenty of airflow UNDER my solar panels, to maintain optimal performance. These are the primary reasons for the system I build. When you think about the stresses placed on an awning, both when closed and driving, as well as when deployed, the rack is a necessary part of the system. These two Transits are utilizing the minimum componentry up on the roof. I will focus on additional structure to accept the added 70 lbs. But as I mentioned earlier, I think the added weight up there is more detrimental to the balance of the van, the center of gravity. So to counteract that, we need ballast downstairs. I need to bring the center of gravity back down to a level commensurate with the original deign of the vehicle.
Thanks for creating such useful content for the community! Has anyone asked you to reinforce a roof? (Noted, comment on center of gravity; but more so for static load - rooftop deck.) I mean, how often do people climb up on to their roofs anyways? But looking at the weight limits, seems questionable to have a rack, some gear, and two adults on any roof, regardless of which manufacturer.
I would not reinforce the roof structure, giving a sense of confidence that the excess weight is now acceptable. I would say that MOST van builds with rooftop decks are severely over weight. I have a hard rule not to alter the chassis of any of my van builds. I would be liable for any damage or injury.
Do the awnings always get mounted on the roof racks? Or are there other options? I would love an awning on my future van and wanna be sure I build it correctly.
Awnings can be mounted directly to the van roof. Many (most) manufacturers mount this way. I prefer rack mount (called wall mount) because they do not add holes through the roof, and they are adjustable in the way you mount .
@@HumbleRoad I guess I would be better off with the roof rack then, since that Transit roof is so thin. I think I would prefer to do it myself though, so I can be sure it's all properly sealed. Thanks! 🙏🏽
In the Home Depot, duct tape is $6.00 a roll. Gaffer's tape (called cloth tape in the old days), in the film industry is $15.00 a roll. Pretty much the same stuff.
Just took delivery of the 8020 material last week. Battery and assorted electrical shipping early FEB. Believe me, I'm very excited to begin those two munchkins!
This is the rack I wanna get. I am also putting in an ac. Should I buy the rack and install it first so I know where to put the ac? I know flatline has the panels you put in the rack so you can stand up there so want to position it correctly.
I was not happy with the width of these racks. I spent much time fabricating new spacers to widen the distance as much as I could. Go look at Orion racks. I just purchased one for Roxie, but have not installed yet. Keep an eye out for the video. But I do not recommend the Flatline.
Silicone will be fine with the pad. I would be more concerned with the exposed metal from the Dremel. I would think it should have some prep to avoid moisture getting in there and rusting a point of support.
Hi just had a question about the weight. I understand your concern about the weight on the rooftop, but how does the weight of the ceiling only being a few inches below affect your calculations?
It’s all about center of gravity. If you notice the low roof transit has a much higher weight capacity for the roof than the high roof version . If you think about it, they’re both made with the same gauge materials. It’s just that the high roof has a higher center of gravity, so you have to work with a lower weight capacity. The roof can take the way you just have to make sure you keep your center of gravity low and you’ll be fine.
Hein at diyvan needs some competition. His prices are outrageously high. For any product he sells that you can get elsewhere, like insulation, thinsulate, mini cell etc……you can find it cheaper. I really wish someone else would make spacers too to bring down the price.
The components on the roof are the minimum required, with none being unneeded. As illustrated, they add up to be more than 70 lbs over the manufacturer's rating. This will be an ongoing issue with the Ford Transit as a platform for building. I will add additional structural support to compensate for this shortcoming.
thanks for taking the time on all the videos George. was going to ask about the 73 lb's overweight. makes me wonder if other convertors are reinforcing the Transit roof ? guessing not.
I've seen that Flatline also offers a "safari" roof rack that has a deck. I was originally leaning toward that, but after watching your video I'm wondering if the transits roof is flimsy enough that the safari version of the deck would be a bad idea? Or perhaps the weight is distributed evenly enough that it would be ok?
RV's badly need an alternative AC/heatpump system that is affordable and not roof mounted. Could use a compact mini-split type or window type that deploys thru a side hatch. I believe I saw a motorhome with an LG split system integrated in the sidewall. Better yet would be making use of the vehicles AC if it had an electric compressor. Tesla's allows similar capability for their dog mode.
Personally for boondocking or full-time use, I would minimize the roof holes and maximize area for solar. I would only consider one opening for a marine hatch for stargazing, roof access or lookout. I can think of viable alternates to roof fans. I like the idea of tilting or sliding solar panels to uncover the hatch and roof deck. Sliding panels side or rear could act as a mini awning.
@@coopcraige this is the first Transit roof reinforcement I’ve seen beyond what George already does with wood supports to accept the screws for fan/AC installs. By the BEMM, seems like a structurally sound method (he did a pull-up for goodness sake!). It totally blows my brain on how I started designing my ceiling panels though 🤣 back to the drawing board if I decide I need angle aluminum.
I’m planning on a maxxair in bay 2 (bay 1 is the curved bay) and was leaning to the Dometic RTX 2000 in the rear most bay with Hein’s DIYVan adapter. Maybe with that layout I don’t need those angle supports… maybe. I need to research that more.
@@YT-MY Yup, an easier and cheaper AC unit, window mounted, could be this Eurom 2401.
Also, what van people DO NOT understand when mounting solar panels on the roof, be it secured flat or rolling some to catch that sun, is that most of the time they’ll need to park under a tree for shade. Otherwise in the summer sun the exposed surfaces are huge, to the point that any AC would not be efficient!
Therefore, it would be best to have some sort of mobile/tilting/side mounted solar panels that could either follow the sun by adjusting the angle or even move to opposite van sides.
Leave the van under the sun in the summer to produce electricity that is spent to cool that van down again, seems absurd in my mediterranean eyes...
“Be a man and use real tools” … George you make me smile
When the manufacturer doesn't specify a torque setting, I usually go by the German torque standard commonly referred to as "gooden tite".
George, you’re the best! Intelligent, thoughtful and skilled. Your customers are so lucky!
Thank you Edith!
If your boss hasn’t told you today, bro you’re doing a great job thanks for the video update I always look forward to seeing what you were up to!
You bet
Hey George, we share a little bit in common in that I'm a graduate from Brooks Institute. Advertising /Illustration photography and color technology. Nice that you take the time to set up the lighting for these shoots, and even explain to the public. The attention to detail is admirable. Well done sir!
I got lucky, mine were lined up perfectly. Nice rack.☺️
One of the few times it’s acceptable to say “nice rack”. LOL
Camera and lights setup is impressive. Thanks for the roof top install.
You bet
Thanks for the “behind the scene” George
Great work preparation. It's like a surgeon!
All tools and instruments needed for the operation are neatly organized within reach.
I can see the pro photographer is still there in the van builder / TH-camr with the lighting technique.
The DaVinci of Van Builds. Bravissimo Maestro! Such craftsmanship is rare today. This was a treat to watch, including the photo tips. This is the zen of van builds.
I bought a roof rack from Flatline just a couple weeks ago after first considering 8020 and unistrut options. The weight was really the deciding factor for me. They are expensive, but the time and weight saved was nice. It was also already in stock and arrived in 2 days. I was expecting they'd have to be cut to order, so that was a nice surprise to have it so quickly.
I have not encountered a third-party roof rack that’s wide enough to accommodate solar panels, air, conditioners, and fans. I still prefer to build my own racks out of 10 series 8020.
@@HumbleRoad I don't plan on adding an air conditioner, but the rack (extended roof model) easily supports 800 watts of panels, MaxAir, weboost, weather station, and starlink port. The cross members can be placed wherever you decide, allowing for highly customized configurations. It's possible the design has evolved. Nonetheless, I respect your preference of using 8020.
@@NomadicPride sorry what I meant to say is when there’s an air conditioner mounted in the center of the roof. There’s no room on either side for solar panels flanking the air conditioner. I had to cut the flat line rack and spread it and add inserts to the crossbars in order to fit my solar panels. It worked just fine on two Ford transit but I don’t wanna do that every time. Now, I’m going with the Orion roof rack on 24 transits. I’ll let you know how that goes.
@@HumbleRoad Thanks for the clarification! I wasn't totally getting it, but knowing the air conditioner is center-mounted brings it clear. While I'm in for the FVC rack now, I'd still love to hear how the Orion does.
Excellent workmanship and details with pride in everything you do with utmost superior class and quality👍.
Thank you so much 😀
A little touch-up paint on those elongated holes you made would be good as a barrier against rust....
thanks for showing the setup for filming.
many people fail to realize it takes twice if not three times as long,
to document your stuff as it does to plan it out and successfully complete the task itself.
--great quality-- happy new year and continued wellness.
Thanks for showing the camera set up, lighting makes such a difference. 😋
You bet!
In the not too distant future, you will see a lot more awnings designed to also have mosquito netting all around.
That is a design challenge, but a real necessity in so many areas in the summer.
Thanks for the extra lesson in photography! 👍
Thanks for the lighting detail. I remember you saying you were a photographer in your previous life. I think you said you did commercial work??? I owned a Portrait Studio for 17 years (Families, babies & High School Seniors).
Great lighting often, and should, goes unnoticed. Poor lighting is always noticed. Your attention to detail is very much appreciated.
Thank you sir, I had learn a lot in building a camper from your channel Humble road...from 🇲🇾 the trend is coming now...
You say flat lining is the last thing you want to do and ironically it exactly the last thing you will do someday. Hopefully not anytime soon cuz I love your videos and soaking up your wisdom.
You have supreme taste in style and design. I searched 12 years for a roof rack and when I spied one in the Pearl I buttonholed the owner to know the producer (FVC), local, a few miles away. Their business model is trim and efficient but their customer service is sterile like so many today. Their products aren't as good as you would produce but I've not found better in the last two years. My years in metal trades makes me think Flat Line refers to a positively square angle. IOW, damn straight.
Since when do van vids provoke hilarity along with a valuable educational experience? Since Humble Road of course :-) Thank you George for the insight and the laughs and the overall impeccable quality! Flatliner out.
Glad you enjoyed it!
Love your editing/milkshake making station
George, you're a Van Build Rock Star !!! thanks for the video !!
Wow, thanks!
Thanks for all the great work George. Having just purchased a Transit, I can’t tell you how excited we were that you are doing two of them now.
Stay tuned!
Thank you for this video! I will be installing a Flatline rack on a Transit soon and learned so much from this!!!
Thanks George, nice rack install. As detailed as you are I don't understand why you can't cook. That's right, I said it again.....cant help myself....
Ha! If I set my mind to it, I could most likely become a good cook. At this point in my life, it doesn't interest me to the point of doing the "deep dive" as we say these days...
Per the BEMM all of the roofs are rated to the same 420lbs, the owners manual derates the high roof to only 220lbs based on the center of gravity of the factory configuration. Ford expects upfitters to do their own center of gravity calculations based on the formulas in the BEMM and adjust the available roof capacity based on those.
Details and highlights with George!
School is in session. I'm taking lots of notes. Thank you for these detailed videos!!!
You are so welcome!
Harmonics are important.
Wind-induced harmonics brought down the original Tacoma Narrows Bridge for which there is film footage.
I think about vertical springs on top of the roof and under the frame with round rubber feet at both ends.
You're too much... I love it! Thanks for the recommendation on the Transit rack. Planning my build right now so compiling my list/resources of must haves, and this is definitely one! 👍
So thanks 4 the break down on the lighting set up n camer angles, n your general due diligance the thing 2 consider re rain is angle of rest of the van it may not alway park so it maintains perfect flatness alao what was happening in the past is no where indicitave of whats poszible now expecy much more erattic weather things like massive hail dumps followed by 2 inches of rain in minutes become fairly common
Attention to detail is top notch.
I'm seeing rubber hockey pucks being used as cushions in roof rack systems. I'd like to know your thoughts. They also used silicone on body under puck.
I haven’t heard of that and I’d have to give it some thought as to whether or not it’s necessary and if so, is this the best solution
It is so nice to learn there is another person that notices there is a "proper" orientation for washers!!! Great info as always George.
I didn’t know there was a proper orientation either. But why does the polished side face the nut? Shouldn’t the polished side face out? Or is it polished to show the user this is the side that needs to face the nut? Thanks
I say “Ne Ne”! 🤣 Good morning!
Good morning, Lynne!
Hey great info. I see Flatline has some stuff on sale right now. Very reasonable prices. Thanks George. High thumbs up on the production insight at the end!
Cool, thanks
Hi George
Enjoyed your Roof Rack Install Video .
Looking forward to The Next One !
Thanks
Glad you enjoyed it
Good to see you work with so much care and finesse George. Not kidding with the tin construction of the Transit. I had to build a surveillance vehicle on a high roof. Had to install a 15m pneumatic mast in it which was huge and very difficult to stabilize in the vehicle structure. Even the crew/operators compartment was a nightmare as rivnuts don't hold well in the flimsy inner frame. I have also noticed that corrosion on the underside is a potential issue. The van has now done around 30k and only has light use as well. Maybe the US ones are better than the UK vans? Keep up the good work.
Gals play with real tools too George… lol! Like a real man.
No one can say enough about your precision, skills, organization, and self-marketing. You're the best George. My inspiration and (difficult to reach) benchmark for my DIY Sprinter Motorhome. Thanks for sharing.
I wish you the best of luck with your van build. Go slow! Take your time!
Looks like those van windows could use some limo window tinting. Nice demo on the roof racks. 👌
Yes, that window van will be living in southern Florida. Ceramic window coating is in the plans.
How much weight savings is there compared to 80/20 as the backbones? Have you used 1.5"x3" (40/80series), run upright for backbones? You have really good & helpful data in your videos.
Thank you for another great episode. Not only do I enjoy the content and your meticulousness of your builds but also the care with your video production. BTW, you should do a few lightning tutorial videos for youtubers.
But mostly I enjoy something intangible of your personality and humor. I get in good mood watching every one of your documentaries. This is top notch!! Thank you.
Thank you Pierre!
You just keep on giving and instructing ... custom vans and ... as well as now - videography! Thanks you, for all you do, and most of all, all that you share.
Such great info as always. I really thought you were going to yell, "Makeup" during the lighting part of this video.
Again, another great video. The ending shows you passion still fro photography and lighting. Well done sir.
Just wanted to say that I think your videos are great.
Hi George, love your videos. Have you ever seen how Embassy Vans have the air-conditioner as a split? Inside and under.... pretty cool...
I’ll wait for the three year review
Great minds strike again! I too settled on FVC for my roof rack; waiting to see what their new model coming at the end of January brings to the table.
Pretty sure those bolts from mounting bracket into the van holes are M8.😉
Great vid both informative and entertaining as always, George!
Informative as ever 👍👍
Great to see your pro photog tips and the fact that you spend a great deal of time in the production side of your videos (unlike most all utubers). Being from the south where its hot most of the year, air cooling is something that is necessary. I'm surprised you haven't switched to something more efficient than those noisy watt hogs that most RVs use. A good high-SEER (120v or 12v) mini-split uses about half the power, is far quieter, and also provides heat when needed. Additionally, they don't add height and top heavy weight to an already tall vehicle. On the other hand, they do require something you love to do - solving the problem of where the 2 main components are installed! Keep up the good work and be careful on the scaffolding - perhaps a safety rail around 3 sides would add a layer of insurance for you and your employees.
Hey George! Thank you for enlightening us! And for other tips and advice. Maybe I'm just going to rent one room just to put some things together. And maybe put my snow-covered pickup truck in there too.
Go for it! 😁
Copernicus..!
Exceptional work and video, no one does it better! 👍
Great job, but still waiting to see the mini me !
I'm working on it! The 8020 material just arrived last Thursday
Your technical thoroughness is amazing... you make shortcut a 4-letter word! I’ve been looking at manufactured and diy used vans for a little while, but your videos have set a standard that makes it hard to settle for less.. Thanks for the masterclass!!
You are so welcome!
Now I feel like my FVCO rack choice has been blessed by the pope!
I added the front FVCO faring option to break the wind on my front roof fan. And it looks cooler than a bar. 😉
I so appreciate the time you put into posting videos when you are so busy managing your van build family. Quite admirable, especially with the care spent your professional lighting. I have yet to start editing my van build footage. I’m slow enough as it is! But I love the puzzling process. I look forward to showing it to you when I finish it - probably around 2025😝 It has been the Perfect Pandemic Project.
Big thanks for the 'behind the scenes' segment! Would love to see more of those, also involved on the shop side. I'm vey curious how you have material storage in the shop for wood and aluminum, both sheet and stick product.
Just to quench your thirst; I don't bulk purchase materials. ALL material is ordered/purchased per van, for that van. I don't inventory anything! Great for cashflow! So, as I receive it, we build it and install it.
@Humble Road Thank you so much for sharing your lighting setup. Are the lights fluorescents? I enjoy your content so much, and the BTS is the icing on the cupcake.
I just asked a question on your video: “Custom Van Build - FORD TRANSIT - High Roof Rack, Weight Issues and Fan Leveling Gaskets.” I thought this might help for your time and troubles. Thank you!
Thank you!
1) 0:43 TOTAL WEIGHT LIMIT HIGH ROOF EXTENDED CHASIS: Transit 220 lbs, Promaster: 330 lbs, Sprinter: 330 lbs.
2) 0:47 Fiamma 45S 10’ awning = 49 lbs. 100 watt solar panels = 57 lbs.
3) 0:55 Flatline Van Company roof rack = 65 lbs (which is lighter than a custom 80/20 rack because the Flatline rails are lighter than 80/20 rails. Flatline roof rack will use 80/20 crossbars.) This rack is pre-made to accommodate the Fiamma awning and solar panels.
4) 1:27 Rack 65 lbs + Awning 49 lbs + 4 100 watt solar panels 57 lbs + 2 Maxair fans 40 lbs + AC 82 lbs = 293 lbs.
5) 1:42 Installation of Flatline roof rack on For Transit begins…
Another informative video. Hey George, since I have been a fan “from the beginning,” I know your first career was as a profession (top in his field) photographer. That is why your videos look like you hired a videographer when all time you are both the guy behind the camera and the guy in front of the camera!
I appreciate that! Since I love doing both, I'm not willing to give up either one!
George, I'm enjoying your Transit conversion. I started my 2020 Transit conversion a year ago, the Flatline roof rack was my first installation. I've come across one challenge ... the bolts that connect the 80/20 1010 rails are frozen ... at least one of them is, it's been stripped out, and I haven't found a way to get it out. It's the only failing part of the FlatlineCo roof rack for me.
Shave the head off lubricant on the threads and back it out with channel locks
(Square the head)
That rack system looks great! Although it seems like the roof rack will make it more challenging to get the A/C in position.
Yes it will. But I work smart, not hard! Stay tuned!
@@HumbleRoad hmmm, maybe ply spanning the crossbars? I'll be watching!
Fantastic video and nice product.
My feeling is weight is everything, like a serious backpacker or bicyclist. Quality and lightweight do not have to be opposites. My thinking is why carry excess weight, it stresses the vehicle, can degrade vehicle safety and limits what necessities you can carry.
Is that bare metal exposed around the roof holes? I would paint any bare metal to limit future rust.
It would be interesting to measure the thickness of the different van roofs. Looks like the Ford has greater flat area down the center for better opening/mounting options.
Yes, that flat area going down the center of the roof is precisely why the roof flexes so much! Folds and creases in the sheet metal provide rigidity.
Love your videos. Your the larry david of van building
pretty...pretty...pretty...good!
Nice vid George 💯...now I wonder if all the others that mount waaaay over 220 pounds up top have reinforced their setup at all....or just "wingin it"...???
Roof weight limits are the dirty little secret of van building. I see many vans waaaay overweight up there. And the 220 lb limit on the Transit is a big problem!
George that is a nice rack. I've seen videos of vans with walkable solar panels. It's called a deck. I believe they are on a Sprinter. With one person it would be too much weight.
Looks like you will be over weight on the Transit van.
Yes, I'm approx 70 lbs overweight right now. I'm going to add structural support to compensate.Thankfully, my clients are not Formula One drivers...
Nice-nuts, I didn't know! So there's a gap between the bottom of the roof panel and the start of the "plus nut" threads? If water were to get past the silicone and the foam pad, wouldn't it leak into that void? Where is that void inside the van, in a roof rib or support strut? If that's the case, does that water drain out through a weep hole or into the insulation?
My free advise, worth exactly that, is caulk the whole perimeter of the AC: Wind driven rain and the occasional high pressure wash will force water uphill.
Oh make no mistake! The entire gasket is glued and sealed all around. And that's where you could stop, particularly with 3M5200 or 3M4000, you should never have a problem. But I go a step further, and you are correct, that driving rain is very smart! It can find it's way into the slightest of voids!
But to answer your question, The holes are located so far outboard that any leak would run down the wall down into the weep canal under the floor. But I will not allow that to happen!
Beautiful, great stuff. ✌And hope you're having a great New Year.
Thanks! You too!
QUESTION: I have a 2023 Ford Transit Trail. It comes stock with the MaxxAir Fan between the front two support ribs. I wanted to put an A/C unit in the middle section of ribs (which happen to be the farthest spaced), and you mentioned fabricating some supports for the weight of your A/C unit. Would you share what your solution is to this issue? Thank you! Truly enjoy your videos!
I went a little overboard with my solution to spread the load across the ceiling. Additionally, I incorporated it into a design move, running a boardwalk, all the way down the center of the ceiling see the video. Custom Van Build - FORD TRANSIT - Air Conditioner? Xtra support rails are a MUST-HAVE in these vans!
th-cam.com/video/LoxWc12vcGc/w-d-xo.html
@@HumbleRoad AWESOME!!! You SAVED me from making what could’ve been a HUGE mistake. LOVE your videos! Thank you!
Glad I could help
Did i miss where you painted the roof metal where you enlarged the hole? Rust will happen on bare metal.
love your videos, master class both in skill and language heh heh
Your editing bay looks sweet.
Thanks! I miss that suite, I spent hours and hours in there, very cozy. That was an old clip and I have since given that space over to my son, Andrew. He turned it into a bicycle mechanic's room. He's a bicycle racer.
@@HumbleRoad Would love to see a short video on your current office setup at some point!
OK, right now I'm in the process of putting together a control console to improve my editing skills. I'm dedicated to taking my videos up a notch in both content and quality this year.
@@HumbleRoad LOL. I’m still laughing about all the lighting. I’d just like to replace those awful PW lights.
@@HumbleRoad Just don't lose the cheesy sound effects, transitions, and jokes in the process ;)
Now that you have some experience with both your own 80/20 and this flatline branded rack, I am curious about your thoughts on using a plate rail vs an extrusion for the outside rails. Plusses and minuses...prefferences...
From now on, I will build my own racks. That’s all I will say…😡
I keep the tools that they sent and put it a tool bag for the new owener in case they have to make a repair on the road if they need to.
You know you threw me into a tailspin! The 220 lb weight limit on the roof isn't about the walls crumpling or any of that - it has far more to do with how top-heavy the van can be on the road without tipping over on corners! I started planning on fortifying the ribs and got way into it until the coin dropped and I realized - this isn't its structural limit it is its _practical_ limit.
You did say near the beginning "perhaps because of how tall it is" and that is totally what it is.
How's your build going? I'm debating a similar notion - as I plan to make the van's center of gravity lower (for driving), but for static situations, I want to have the roof rack, solar, and a possible deck we might even be able to stand on. =)
What are your thoughts on the Unaka rack? Considering it over the Flatline.
George, would it be an option to use brackets on just one side for the awning and utilize plastic, glue-down mounts for the solar panels (assuming you have the roof real estate)? This would eliminate the crossbars and at least one side of the rack. I’m also working to reduce weight as much as possible. Trying to avoid a roof rack entirely. Always a pleasure to watch your videos!
I prefer a "wall mounted" awning rather than the "roof mounted" variety. And I like to keep plenty of airflow UNDER my solar panels, to maintain optimal performance. These are the primary reasons for the system I build. When you think about the stresses placed on an awning, both when closed and driving, as well as when deployed, the rack is a necessary part of the system. These two Transits are utilizing the minimum componentry up on the roof. I will focus on additional structure to accept the added 70 lbs. But as I mentioned earlier, I think the added weight up there is more detrimental to the balance of the van, the center of gravity. So to counteract that, we need ballast downstairs. I need to bring the center of gravity back down to a level commensurate with the original deign of the vehicle.
Are you saying that lock washers have a top and bottom? Learn something new every day!
Thanks for creating such useful content for the community! Has anyone asked you to reinforce a roof? (Noted, comment on center of gravity; but more so for static load - rooftop deck.) I mean, how often do people climb up on to their roofs anyways? But looking at the weight limits, seems questionable to have a rack, some gear, and two adults on any roof, regardless of which manufacturer.
I would not reinforce the roof structure, giving a sense of confidence that the excess weight is now acceptable. I would say that MOST van builds with rooftop decks are severely over weight. I have a hard rule not to alter the chassis of any of my van builds. I would be liable for any damage or injury.
Do the awnings always get mounted on the roof racks? Or are there other options? I would love an awning on my future van and wanna be sure I build it correctly.
Awnings can be mounted directly to the van roof. Many (most) manufacturers mount this way. I prefer rack mount (called wall mount) because they do not add holes through the roof, and they are adjustable in the way you mount .
@@HumbleRoad I guess I would be better off with the roof rack then, since that Transit roof is so thin. I think I would prefer to do it myself though, so I can be sure it's all properly sealed.
Thanks! 🙏🏽
"I don't understand how it could be that far off." I guess this is his first Ford.
Could you do a video on your margins and running the business?
😳
That is photographer light system. Just missing duck tape. :D
In the Home Depot, duct tape is $6.00 a roll. Gaffer's tape (called cloth tape in the old days), in the film industry is $15.00 a roll. Pretty much the same stuff.
Need to see Mini-me Van (Ram Pro-Master City)
Just took delivery of the 8020 material last week. Battery and assorted electrical shipping early FEB. Believe me, I'm very excited to begin those two munchkins!
This is the rack I wanna get. I am also putting in an ac. Should I buy the rack and install it first so I know where to put the ac? I know flatline has the panels you put in the rack so you can stand up there so want to position it correctly.
I was not happy with the width of these racks. I spent much time fabricating new spacers to widen the distance as much as I could. Go look at Orion racks. I just purchased one for Roxie, but have not installed yet. Keep an eye out for the video. But I do not recommend the Flatline.
Thank you for letting me know! I will go look at the Orion!
Should I install a roof rack before the ac so that I know exactly where to put the ac?
@@HumbleRoad doesn't look like they make a transit rack on their site.
Silicone will be fine with the pad. I would be more concerned with the exposed metal from the Dremel. I would think it should have some prep to avoid moisture getting in there and rusting a point of support.
I prime all cuts and drill holes.
Hi just had a question about the weight. I understand your concern about the weight on the rooftop, but how does the weight of the ceiling only being a few inches below affect your calculations?
It’s all about center of gravity. If you notice the low roof transit has a much higher weight capacity for the roof than the high roof version . If you think about it, they’re both made with the same gauge materials. It’s just that the high roof has a higher center of gravity, so you have to work with a lower weight capacity. The roof can take the way you just have to make sure you keep your center of gravity low and you’ll be fine.
Probably named Flatline because those side members are formed from steel plate rather than tube or extrusion.
George, you are just amazing! IMO Ford as an RV van is not ideal! But then, I wouldn’t own a Ford.
The problem with MB is their dealers are no George. They have let me down, at least the one I have to go to, routinely.
Having content like this helps all properly plan and navigate the weaknesses of any manufacturer's platform.
hey legend what the name of the roof rack and the company who sells it ? thank you
I cannot recommend that rack because of the design. Sorry!
Is that a m6 or m8 thank you
What color locktite did you use... it looked like red.
The tube is red but the locktite is blue.
Hein at diyvan needs some competition. His prices are outrageously high. For any product he sells that you can get elsewhere, like insulation, thinsulate, mini cell etc……you can find it cheaper.
I really wish someone else would make spacers too to bring down the price.
I can agree with that.
Hello, can you please post a link to the item? Thanks!
Where do you suggest to purchase 8020 aluminum?
I purchase direct