Building a DIY Roof Rack with 8020

Utilizing the specific extruded aluminum brand 8020

We recommend completing the prerequisites before continuing your journey through the steps:

The curve of your roof – since not all van roofs are flat, the roof rack will need a bracket that will enable the cross beams to sit evenly. We used (and recommend) the Unaka Gear brackets, but you can do your own research for what might work for you. The brackets will need to:
Be tall enough to accommodate the curve of the van
Be sturdy enough to bear a lot of weight
Layout of your solar panels
2 or more people – this gets heavy and involves some simultaneous work in order to fit the solar panels to both sides of the roof rack

The Roof Rack

PREP THE ROOF:

Remove the plugs covering the 10 M8 factory threaded holes
TIP: applying a small amount of heat using a blow-dryer or heat gun to the plug will loosen things up a bit and make it easier to remove
Clean any residual glue off
Using a filer or grinder of your choice, expand the edges of any holes that are not aligned completely
Touch up with primer to prevent rust

INSTALL SIDE RAIL BRACKETS:

Loosely fit all 10 brackets with a M8 bolt (13mm hex socket) and a sealing washer to ensure everything is fitting properly
NOTE: If you're using the Unaka brackets, they can be installed facing either direction, depending on if you want a slightly short, or slightly longer distance.
Once things check out, apply thread locker to each bolt and screw them in
Apply lap sealant around each bolt to prevent any moisture from getting in

CUT and TEST FIT SIDE RAILS:

Measure and cut extruded aluminum to the desire length of roof rack
Slide T nuts into each rail (the amount of t nuts needed will be depending on how many bolt holes your brackets have...unaka has 2 per bracket.
Bring rail up to the roof and align the t nuts to each bracket
Screw in each bolt LOOSELY making sure they grab the T nut
Do not apply thread locker yet! You will still need the side rails to slide back and forth during the solar panel attachment

CUT and PREPARE THE CROSS BEAM RAILS:

Using the dimensions of your solar panels, measure where cross-beams will have to get installed on the roof in order to support the solar panels
Measure the distance from one side rail to the next in that each spot that will need a cross beam
Cut your 15 series 80/20 that distance and label them in order of where they need to go (this way you don't confuse them, although they should be the same distances since the side rails can't curve)
Repeat for each cross-beam needed
Attach an L bracket to each cross-beam using a T-nut and bolt. Do not attach these to the side rails yet.

Attaching Solar Panels

OPTIONAL: Attach solar panels together for, heavier, but easier install <<Revisit>>

In an open work station, configure your solar panels side by side
Down the middle, mark where you plan to drill holes and screw the panels together

ATTACH BRACKETS TO SOLAR PANELS:

CUT and PREPARE THE CROSS BEAM RAILS:

Using the dimensions of your solar panels, measure where cross-beams will have to get installed on the roof in order to support the solar panels
Measure the distance from one side rail to the next in that each spot that will need a cross beam
Cut your 15 series 80/20 that distance and label them in order of where they need to go (this way you don't confuse them, although they should be the same distances since the side rails can't curve)
Repeat for each cross-beam needed
Attach an L bracket to each cross-beam using a T-nut and bolt. Do not attach these to the side rails yet.

Get assistance from another person as the wooden slats are long and awkward to hold and attach to the ceiling crossbeams by yourself.
You'll be holding your arms above your head for a long time as you're working on the ceiling, take breaks so you don't tire out
Be sure to wear safety eyewear since gravity is not your friend in this install guide (lots of particles falling down into your eyes)