We’re building a Super High Roof ProMaster Van into our dream home for full time van life travel! 🏔️ In this episode, we install rear door windows, build a budget-friendly DIY roof rack, and upfit the van for off-grid power with 800 watts of solar panels ☀️🚐
Episode 172 | Filmed March 2025 | Van Build Ep. 2
Windows
- Window (Passenger) - https://amzn.to/4cI9xG7
- Window (Driver) - https://amzn.to/4jeljKt
- Urethane (1 tube per window) - https://amzn.to/4i6yhsP
- Edge U-Trim - https://amzn.to/42I2uIV
- Caulk Gun - https://amzn.to/3D0xsTx
- Primer Paint - https://amzn.to/3E879LM
Roof Rack
- Half Strut Channel (10ft x2) - https://tinyurl.com/crbwhx9f (THD)
- 3/8” Hex Bolt (x8) - https://www.homedepot.com/p/3-8-in-16-x-1-1-2-in-Galvanized-Hex-Bolt-15-Pack-805530/204281466 (THD)
- 3/8” Lock Washers (x8) - https://www.homedepot.com/p/Everbilt-3-8-in-Galvanized-Lock-Washer-50-Pack-804160/204284554 (THD)
- 3/8” Flat Washers (x16) - https://www.homedepot.com/p/Everbilt-25-Piece-3-8-in-Galvanized-Flat-Washer-802284/204276381 (THD)
- 3/8” Hex Nuts (x8) - https://www.homedepot.com/p/Everbilt-3-8-in-16-Galvanized-Hex-Nut-25-Pack-802244/204274099 (THD)
- Butyl Tape - https://amzn.to/4i6apFB
- Rubber Washers (x8) - DIY
Solar
- Solar Panels (200W x4) - https://amzn.to/42RaOHh
- Solar Cable (20ft 10awg) - https://amzn.to/3QWjRQw
- 1/4” Hex Bolt (x16) - https://www.homedepot.com/p/Everbilt-1-4-in-20-x-1-in-Zinc-Plated-Hex-Bolt-100-Pack-800590/204273584 (THD)
- 1/4” Lock Washers (x16) - https://www.homedepot.com/p/Everbilt-1-4-in-Galvanized-Lock-Washer-100-Pack-804140/204276472 (THD)
- 1/4” Flat Washers (x32)- https://www.homedepot.com/p/Everbilt-1-4-in-Galvanized-Flat-Washer-100-Pack-807270/204284543 (THD)
- 1/4” Hex Nuts (x16) - https://www.homedepot.com/p/Everbilt-1-4-in-20-Galvanized-Hex-Nut-25-Pack-802224/204276133 (THD)
- 2-Hole Strut Connectors (x16) - https://amzn.to/3GhG3mg
- 3/8” Hex Bolt (x10) - https://www.homedepot.com/p/3-8-in-16-x-1-1-2-in-Galvanized-Hex-Bolt-15-Pack-805530/204281466 (THD)
- 3/8” Lock Washers (x10) - https://www.homedepot.com/p/Everbilt-3-8-in-Galvanized-Lock-Washer-50-Pack-804160/204284554 (THD)
- 3/8” Flat Washers (x10) - https://www.homedepot.com/p/Everbilt-25-Piece-3-8-in-Galvanized-Flat-Washer-802284/204276381 (THD)
- 3/8” Nylon Strut Nuts (x10) - https://amzn.to/4jEpizS
Tools
- Jigsaw - https://amzn.to/4i7Yt65
- Circular Saw (brushless) - https://amzn.to/43GIFDY
- Sander - https://amzn.to/4hZ0LEs
- Router - https://amzn.to/4li2WpD
- Masks - https://amzn.to/3Ykoh7P
- Overalls (women’s) - https://amzn.to/43Ihs3B
- Overalls (men’s) - https://amzn.to/3YnEbOT
** some of the links above are affiliate links, which means we earn a small commission if you use them — at no extra cost to you.
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Chapters
0:00 - Super High Roof ProMaster Van Build
0:32 - Rear Door Windows
4:12 - Cutting Holes for Windows
7:38 - Window Install
11:29 - Results
12:55 - DIY Roof Rack
14:40 - Saving $1800 on a Van Roof Rack
17:56 - Half Channel Struts (Low Profile Roof Rack)
19:55 - Solar Panel Install
22:58 - Testing 800W Solar Panels
24:29 - ProMaster Secret Cable Entry
26:09 - Surprise Visit from Supervisor (bloops)
#vanlife #vanconversion