Fantastic Fan Replacement
Well I finally got a minute and put the van up (after 7 hours of moving toys) and tore into the fantastic fan. It's been leaking since forever and I basically found exactly what I expected.
Here is what NOT to do:
1. drill your corners vertexes when cutting a hole in the roof leaving jagged half holes at every corner. don't flatten out the metal either, just leave it tormented at your cuts.
2. when you paint the edges use bedliner so nothing else sticks and seals to it. as a bonus DON'T actually paint the edges you cut, just you know, on top of them.
3. mix foam, tape, regular glue (gorilla glue) randomly before putting on your roofing tar to ensure there are lots of gaps and cracks and it will never actually seal
4. shove random chunks of whatever is handy scrap in around the cut- wood, old foam, bits of reflectix. be sure to just leave it loose and not actually support the roof.
5. crack the frame because tighter screws are better screws
6. ignore the problem for years even though it was obvious the PO was a hack (d'oh)
So now I have this beautiful ragged hole to fill. It's 14.5" front to back, 14" across and 3" depth (roof to ceiling). Going with an identical fan-tastic FV803350 with the manual controls.
In any case that's where I am- clean but not sanded. I need to put something back on the metal that will stop rust but still allow adhesion, POR15 maybe?