DIY Custom Van ROOF Deck - Less than $750 and Perfect for a Camper Van - Van Build Ep 43

The 43rd episode of our van build conversion series showcases building our custom DIY Roof Deck Platform perfect for watching the sunset and relaxing.
The van is built out of 8020 Aluminum and PVS Composite Decking on the can’s roof rails costing us only $415.45 + PVC Composite Deck $316.29 totaling less than $750!!!
Roof rails: amzn.to/3HHtRJK
Our Solar Setup 400 Watts: renogy.sjv.io/c/3224570/12008...
Check out other van build episodes in our
Van Build Series: • Van Build Series
Subscribe! / @mathersonthemap
If you have any questions, please leave a comment below and if you enjoyed this video or found it helpful, please give it a like!
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Below are the EXACT 80/20 Components we used:
SKU: 1502-LS
1.50” X 1.50" Lite Smooth SurfaceT-Slotted Profile - Two Adjacent Open T-Slots
Length - 54.5 Inches (1384.3 Millimeters)
SKU: 1503-LS
1.50” X 1.50” Lite Smooth Surface T-Slotted Profile - Three Adjacent Open T-Slots
Length - 54.5 Inches (1384.3 Millimeters)
SKU: 1503-LS
1.50” X 1.50” Lite Smooth Surface T-Slotted Profile - Three Adjacent Open T-Slots
Length - 17 Inches (431.8 Millimeters)
SKU: 1503-LS
1.50” X 1.50” Lite Smooth Surface T-Slotted Profile - Three Adjacent Open T-Slots
Length - 18 Inches (457.2 Millimeters)
SKU: 4302
15 Series & Ready Tube 2 Hole - Inside Corner Bracket
QTY = 20
SKU: 4332
15 Series & Ready Tube 2 Hole - Gusseted Inside Corner Bracket
QTY = 10
SKU: 4307
15 Series 2 Hole - Straight Flat Plate
QTY = 8
SKU: 3320
Bolt Assembly: 5/16-18 x .687" Black FBHSCS with Slide-In Economy T-Nut - Offset Thread - Black Zinc
QTY = 80
SKU: 1503-LS
1.50” X 1.50” Lite Smooth Surface T-Slotted Profile - Three Adjacent Open T-Slots
QTY = 10
Length - 2 Inches (50.8 Millimeters)
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Subscribe to our channel, if you want to watch our entire van build/conversion!
Blog: www.MathersOnTheMap.com
Instagram: / mathersonthemap
Facebook: / mathersonthemap
Music: Infinite by Valence

[@APHATMOUSE]

You what a huge bonus of your idea is? Easy to clean snow off!! I dig it!!

[@MathersOnTheMap]

Right!!!! Super easy!

[@vvkilin]

This is the best roof rack/deck/solar setup I've ever seen! Thanks a lot for list of parts!

[@MathersOnTheMap]

You got it thanks for watching!

[@chooseoutside8586]

Beautiful deck! We haven’t been able to justify a $4,000.00 roof rack, and have been using roof cross bars to carry our boards, but I really like this option! Thank you for the informative video 🤙🏼

[@MathersOnTheMap]

You got it! It’s also nice for sunrise/sunsets and cleaning your panels

[@TMAdventuresT7]

Just what I’ve been looking for, well explained and great touch to any camper-van, all the best from UK

[@MathersOnTheMap]

Thank you! Glad ya found us!

[@Scrambler85]

Looks awesome, well done 👏. I used 80 20 to build my solar panel rack. Its a great product. Definitely a thumbs up 👍.

[@MathersOnTheMap]

Thanks J.G. Appreciate it as always!

[@mjremy2605]

I'm so happy you did this video. I love you guys. Subscribed! I have an older Class C and want to put a deck on the roof and want to use 80/20 rails and the same type of PVC decking as wood is not waterproof. I think it will shade the roof, make it easier to mount solar panels, keep the solar cooler, give me a sunbathing/viewing platform. So exciting. You did a fine job on your roof. The build is impressive. I'm here from Patrick's tour of your van. fyi - I would add a low railing to the deck. Always better to be safe. At the very least, add some grab bars to hold on to in case you slip. Don't leave it so open, its an accident waiting to happen. If you ever need to paint it, use Durabak 18 bedliner paint, a very nice product with some flexibility, unlike Raptor type epoxies. Its a moisture cured polyurethane paint used on boats and by the Navy. It comes in a smooth satin finish, or textured non-slip. Standard colors, nothing too fancy. It is very hard and durable.

[@little_bigadventure3575]

Looks great!

[@ronphipps5694]

Nicely done, thanks for the details. Building out a solar panel / deck / surfboard rack now.

[@MathersOnTheMap]

Thanks Ron good luck with your build 👍🏻

[@TrustNotMyHeart]

This van build is epic!!

[@MathersOnTheMap]

thank you!!!

[@KennethYarus]

Bahaaha! I love the "I am not drinking up here" part well done. I am in a big debate about what to deck my roof rack with and have thought of the plastic wood. Hmm. Thanks for the video!

[@demonhogo]

nice build! Someone else's video using 80/20 used some of those elbow brackets sideways to stiffen everything up.

[@Luisventuralaw]

Greetings from San Diego. I'm working on an idea for safety rails with hinges at the base and with extensions all of which, when deployed, would hold in place and hold together with pins. This would allow for feet dangling over the sides when the rails are up. When down, they could serve are racks. You could probably also install a cradle of some kind to the top side of the rail so that when the rails are in the down position, you could securely strap in your longboard. Rails would also make it safer to sleep on top under the stars. I enjoyed the video. Thanks.

[@MathersOnTheMap]

That’s an awesome idea! Not being able to dangle your feet was one of the reasons I opted not for rails so that’s a great solution for that

[@AwakeningWander]

Great video! I just finished mounting our solar panels using 80/20. I installed 2 Maxx fans so mine was slightly different, but thanks for the great instructional video!

[@MathersOnTheMap]

Thank you!!! Nice two fans is a solid move

[@xzavierfranklin7300]

instablaster...

[@jrubio7745]

You do a great job explaining the process. Thanks! I'll try to use your affiliate links every chance I get. (sidenote, the one for the heat gun is not working anymore)

[@MathersOnTheMap]

Thanks Jose!! We really appreciate it and it really helps us out! 👌🏻

[@30all]

Nice work. Did you use SS screws?

[@byungwoo1003]

I love your roof rack!! I live in NJ and I just purchased Sprinter 170WB. Would you let me know where to order 8020 for the roof? Thank you ^^

[@marctania2349]

Thanks for this video.....really helpful as we design out own deck in our RAM 2500. One question.....what is the roof rail you use? Looks like Unistrut.....but my guess is it's not

[@aaronmckeown4928]

Wondering how you calculated weight limit on the rack and the roof?

[@tylerklein8176]

Is that Timbertech Azek? Trex is 1.89lbs/ft.

[@redtanrt10]

Thanks again for another great DIY project. I'd like to add a platform to the rear 1/2 of my low roof 144 and this is a great option. Seems none of the specialty shops offer a 1/2 roof version and I never thought about the plank systems you used. Question, any excessive wind noise?? thanks! Mike

[@MathersOnTheMap]

I don't notice any noise! Thanks for watching!

[@johnnydavies12345]

I’m also making a deck using the 8020 bars but have mahogany wood instead :) From my research normal screws don’t do well under vibrations but self tapping screws are ideal! Just a thought matey! Any advice I can give you after all the hep you’ve provided👍🏽👍🏽👍🏽

[@MathersOnTheMap]

Thanks Johnny I’ll keep an eye on that. I was thinking of putting thread lock on it but was a little nervous too. Are most self tapping screws pan head?

[@sallygeorge8716]

Love this design! We're plotting something similar. Did you ever figure out tie down points for surfboards?

[@MathersOnTheMap]

Hey Sally and George! Yep! Check out our surfing in Assateague island episode I go over how I do it

[@sallygeorge8716]

@@MathersOnTheMap Thanks! Foldable cleats, very cool. Those waves looked fun, too.

[@lostman65]

thanks for the video. i have been in roof-deck-paralysis for the past three months. i keep wanting to build a deck but i have been worried about the deflection of the 8020 for 54" span. the online calculators, (maybe my estimated point loads i use), tell me that it will deflect way too much. however looking at yours tells me otherwise.

[@MathersOnTheMap]

by deflection do you mean moving or shifting out of place? I haven't had any issues with it!

[@2sherrymoore]

Looks awesome! I love the customization of 80/20 but the thought of planning and designing kind of makes my brain hurt lol! Is there a program or design area that helps with making the design? For example if you don’t know about the 3 sided pieces or the 45° corner supports how do you know to use those? Thanks again for always making such informative videos!!

[@MathersOnTheMap]

Hey Sherry thank you! Unfortunately I’m not aware of one I was just on their website for awhile trying to figure out what they got. But I put exactly what I used in the description below if that helps?!

[@2sherrymoore]

Yes it helped a lot!! Thank you!

[@tamnguyenfamilychannel8711]

Thanks for the video Kevin, Do you have the link for the PVC timer?

[@tamnguyenfamilychannel8711]

I mean timber

[@MathersOnTheMap]

Here's the link! I bought it from a local yumber yard though www.timbertech.com/design/decking-designs-styles-center/?gclid=CjwKCAiAjeSABhAPEiwAqfxURVwg3vbT07tcmF57CDhAHRpBkgskwtzy_cCJkMvBSeU22lvSqfSf_hoCTWcQAvD_BwE

[@phillipmendoza593]

Nice job! Looks great! I'm considering this set up for our new camp trailer. Where did you order your aluminum 8020 from?

[@MathersOnTheMap]

Thanks Phillip! Directly from 8020’s website!

[@othess.2718]

Awesome dude.. Thanks for the idea. Quick question, i was curious why you didnt put any gaps in between the deckboards. I was thinking of getting same material and was wondering about about leaving some space to allow the boards to expand/shrink with the weather. How is it holding up? If you had to do it again, would you put gaps just for space for the timber tech to expand? Thanks

[@MathersOnTheMap]

I doubt I’d put gaps if I did it again. Seems to be holding up just fine

[@tylerklein8176]

I would definitely add gaps. My last roof deck built by a previous owner did not and the natural wood boards ended up buckling and snapping screws. I'd also recommend using "winged" screws or predrilling the wood/composite.

[@mikechon6387]

Great idea and job. Looks superb. I have two questions. 1) You bolted the two aluminum bars along the length of the roof down to the bare roof metal panel? What type of bolts did you use? Did you seal it off with silicone to prevent any water leakage? 2) What is the part used to join the end of the 1 inch piece of the bar to the side of the bar? How is it joined?

[@MathersOnTheMap]

Hey Mike The bolts came with the roof rails check out our roof rail install video, links in the description to the rails we have. 2. It’s all 80/20 pieces I think there in the description of this video!

[@mikechon6387]

@@MathersOnTheMap Thanks.

[@KrennPowerSports]

Where did you purchase the extruded alum ? I can’t seem to find it with a solid top on one side.

[@MathersOnTheMap]

8020.net

[@jessicajun1670]

10:50 lolol

[@ntran2012]

Should have used stainless steel bolt. I built mine with regular bolt and after 2 months, I noticed the bolts start to rust. Ended up remove and replace all with stainless steel

[@MathersOnTheMap]

Hey Katie! The bolts are aluminum which shouldn’t rust but I will keep an eye out on them, good to be safe than sorry!

[@jrubio7745]

@@MathersOnTheMap Actually I think the bolts you noted in your original comment is Black Zinc.

[@jrubio7745]

Nam, did you replace both the bolt and the "offset Threaded Nut"? If so, where did you find those?

[@charlesmoman]

I just installed a Flatline Van Co. roof rack on my Ford Transit. The crossbars are Series 10 8020. I am buying the same deck boards you used. You said you used Spax deck screws and mentioned pre-drilling into your 8020. So . . the Spax deck screws were able to finish drilling themselves into the 8020? I am worried about screws breaking off when I do that. Any advice or tips screwing those Spax screws into the 8020 besides what you said in the video? Thanks!

[@MathersOnTheMap]

Yep I predrilled every hole for the spax screws and didn’t have any issue once pre drilled! Broke a few drill bits though but that’s how it goes! Best of luck!

[@charlesmoman]

@@MathersOnTheMap Thanks so much for the quick reply! I hope to get to the roof deck next week. It will make up an episode in my van build series. But trust me! I will not be doing it with my shirt off! It would scare people. : )

[@burk2]

Hey! Which screws did you use? Have all of the boards stayed tight or would you recommend using bolts instead?

[@MathersOnTheMap]

All the boards are still tight after 5000+ miles

[@burk2]

@@MathersOnTheMap thanks! Sorry if I missed it, but did you mention which screws you used?

[@burk2]

@@MathersOnTheMap k looks like I did miss it. Spax exterior deck screw.

[@yurisichgavin308]

🔧 is Msg

[@yurisichgavin308]

Call.xo

[@randalljmatson]

Have you experienced any expansion problems?

[@MathersOnTheMap]

Very minimal but our Van’s finishing is made with poplar wood which resists warping but we seen a few spots that we need to caulk

[@sallygeorge8716]

Could you get away with a little less than those 2" legs? I'm wondering about the clearance between the roof of the van and the crossbars?

[@MathersOnTheMap]

Any reason you’d want to go lower? 2” makes the deck level with roof vent fan

[@sallygeorge8716]

@@MathersOnTheMap our van has a rooftop AC unit. I’m thinking lower profile is maybe better? I studied your video and it looks like you could do 1.5” legs, but now I’m thinking maybe I’ll go taller, so it’s flush with the AC (8” y’all). It looks like we just missed y’all passing through Charleston, SC. Safe travels!

[@roadrunner4398]

How many of these came with your purchase on amazon?

[@MathersOnTheMap]

What is these?

[@roadrunner4398]

@@MathersOnTheMap ahh sorry. I figured out what I was looking for with the 80/20 roof rails. Your videos are a life saver for my van build.

[@bjhessler162]

Where/who made the ladder?

[@MathersOnTheMap]

Aluminess!

[@bjhessler162]

@@MathersOnTheMap No wonder I love it. I have expensive taste that my job doesn't support! hahaha

[@MathersOnTheMap]

Haha we all have that problem!

[@kellymelrose8527]

that "music" make this un watchable for me

[@MathersOnTheMap]

It’s only 15 seconds long! Don’t let it ruin it for ya! Happy new year!

[@robertd6925]

6:40 where did you get the base rails?

[@MathersOnTheMap]

We got them off Amazon amzn.to/3HHtRJK I’ll add the link in the description