The bolt, washer and the T-nut are all stainless. Since corrosion is localized at the contact point, the larger anodic surface area (anodized aluminum) as compared to the smaller cathodic surface area (ss washer and T-nut) will create a passive coexistence. Since the ss bolt threads are embedded in a like metal, ss T-nut, I don't anticipate any seizing.

One builds, makes mistakes, undoes the work and corrects the mistakes. It's called life-long learning. Doesn't happen to those who no longer do stuff. Their learning curve flattens and life becomes dreary. Waiting for videos on the small van, Mr Humble Road !!!! My expectations are SO high.

It was divine intervention. AMEN 🙏

Thanks!

Oh no. I have to change my hardware on my 8020 roof rack to stainless. Thanks for the tip. Enjoyed your video as always. Thanks George!

George. Who says you can’t work alone? As you grow your passion, knowledge, and business, I see a hoist in your future. You’re always thinking and I envision a few hoists in your future. 😀

I think anyone who has watched George for a while probably has the impression that he’s a solid, ethical guy. Well, here’s a perfect example of that. @3:00 he says, “If I’d said ’no’ to them ... I’d have never learned about those rusty bolts and I would have had an issue here.” He didn’t say that his customer would have an issue long after the van was delivered - *HE* would have an issue. That’s a trustworthy custom van builder. If I was in the market for a custom van and I lived in the US, I’d be on Humble Road’s waiting list. Great work, George!

Always learning, modifying, and improving. The Humble Road mantra. ♥️

When I'm not working with 80/20 I know I can stop by your channel and get my fill. Thanks George.

As my mama says, listen to that little voice. I was watching another KZfaqr last week who had the same rust issues on their rack for the very same reason. Glad you can catch it before the van goes out the door.

I think it's a very good idea to use s/s fasteners on "any" outdoor assembly combined with Lanocote. This product is made with lanolin. That's the grease from sheeps wool. Excel. anti-corrosion, anti-seize, lubricant etc. Totally natural product that works! Especially, if you live near the sea. Comes in a spray can or as a pottle of grease.

Everything happens for a reason 😊 If a pro can learn something new, and redo it, it’s an inspiration when it happens to us. All part of the customizing process. Great well built rack set up. Bravo!

Hey George, thanks for the shoutout! I’m one of your guardian angels (although we are a team of seven, not four). We had a team meeting about that roof rack a couple of days before. At first, we thought it might be a good life lesson to let you fail on that one but then we all decided that it wouldn’t just affect you but all those KZfaq followers, who will make the same mistake. Anyway, keep up the good work George. Try not to keep us so busy-we can only do so much and would love to get a day off once in a while. Oh, sorry making you stub your toe the other day. That was a little guardian angel humor. We all had a good laugh up here!

Your attention to detail is amazing! I Love watching your videos.

3:40 Yep! Just whistle it in place, love it!

Nice. Clean, adjustable and rugged.

Very tidy 👏🏻 I made my Ducato rack from 8020 but used the black 8020 and with black solar panels and a black Fiamma awning same model. It looks great and people don’t notice it especially at night while stealth camping in the city

Thank You, great save to switch out bolts, im keeping on list

I love how universal the 8020 system is

I am always so impressed with he quality of your builds.

I keep visualizing you doing a Ford for me, I love how this one's going. You are definitely sharing the vortex. Good job on catching this future nightmare. 👏

So great that you make the rack neat, light, durable. Your shop also (still) looks great, neat, well organized.

well I did a 8020 rack with my nea320w solar... fit 2x and 2 sets on my roof.... now like you show... one person to lift is easy with those smaller ones... but omg bigger ones are harder.... omg thanks for the video.... shows that My system will work well....:) on my 03 workhorse... just got my batterys in too... :) thanks for the great video.... would love to sit and talk shop some day.... but can't wait to see what comes next... :)

Dissimilar metal issues solved. Smart man

I have the same rolling scaffolding. But I used heavy ratchet straps crossed in X pattern to stiffen really makes a difference in stable feel.

I had the same 3 month rusting issue on a roof rack I built on our sprinter as well from the 80/20 hardware. Had to replace it all and it was a headache! Good catch early on!

Have a great labor day and put your feet up!!👍👍

always something of interest to think about

Very clever design...

Hi George Enjoyed your Rack Build Video !! Thanks !!

“Gardian angel! …. there’s probably 2 or 3 of them watching after me…”. Belly laugh goodness! Thnx

This was an important vlog for me today George. I had decided on 8020 for my roof rack. I real wanted the Rhino roof rack system but it’s so expensive. Message to self; Stainless bolts, washers and T-nuts for roof rack. Cheers from Canader eh!

So jealous of Defining Adventure. I met Eric & Jen through another couple and their youtube channel. Nice people. Look forward to running into them on the road one day in our vans. Also, great vid here. i have to make a custom roof rack for my van and was wanting to use 80/20, but wasn't quite sure the process. This vid helped a lot. Unfortunately, I've still got to make supports inside the van along the ceiling for the rack because it'll be a fiberglass roof I'm working with.

Sweet, we got a shoutout (This is Eric and Jen)! Glad we could help. I’m going to switch ours out too! It was serendipity that we were allowed to visit. It was mutually beneficial.

Very inspiring one day i might build ONE

You should just put bleachers in the shop and let people buy tickets. No need to spend time with them, just put out a schedule and if you build it, they will come.

Boy, that was some masterful ladder-climbing technique. 😂🤣😂

If you're particular about black fasteners, McMaster-Carr carries a series of 18-8 pan head stainless steel bolts that are coated with black oxide. You can easily find 1/4-20 or 5/16-18 that will work on 80/20 hardware, either Philips or hex drive.

I used stainless as well (M8) on my Transit.

Really cool 👍🏼 I've about got all my stuff together to start my roof rack for my solar panels but I've thought long and hard about this because a rv roof isn't enough square feet to have enough solar to run everything all the time. Soooo I decided I'm gonna double stack my roof rack. The bottom will be stationary and the top ones will have actuators. So when I set my rv up, I'll push a button and engage the actuators and they'll fold out. So I'll have 6,400 watts of solar which is perfect. Can't ever have to much power 😂

George, I suggest bolting your solar panels to your 80/20 rails, then mount the rails to your roof rack using connections tall enough to go over your AC and Roof Vent. One flat Solar Array of eight or more 2' panels depending on van length. Make the Solar Panels the highest point on the van, no shade from other components disrupts the panels, and it provides shade to the roof. Mine works perfectly! I can do 80 mph and the solar panels are stable. Elevate the Solar array to accommodate the maximum amount of panels. You mentioned in a previous video you want more panels. It works!

Nice video, roof racks have always seemed a bit confusing…good morning all!

Make it where a second layer of panels can slide out and can be used as shade as well as more power!

Could mount a solar water tank on the other side. Cool build!

Always captivating! You are the 8020 Master!

I would add a layer of Lanocote paste between the SS bolt and aluminum brackets. If they drive during winter or in seaside areas salt will get up there.

Love the waltz music, vienese. Blessing the viewers stopped in to save the rack installation. Beautifull synchronization.

I did an 80/20 roof deck with manual moving solar panels so I could use the deck. I used 12ft lengths of 40 x 120 on the sides and 40x80 across with decking all bolted with stainless

I always use stainless steel nuts, bolts, screws etc where ever possible inside and outside, stops any future potential rust problems.

Yep, already seeing light surface rust on my t-nuts on top of my transit. I can reach them pretty easily and since they were a BEAR to install, I think I'll wait on replacing them. One huge pain in the rear is that as you slide a t-nut with a bolt installed along the 80/20 channel, they want to spin counterclockwise and UNSCREW themselves mid-roof...UGH! Huge pain to keep them from 'running' out and landing on the roof under the solar panels. That's why I'm waiting for a bit...good times.

I see you managed to set up a bit of a scaffolding. Here is not me saying you are old, but with age, we all struggle with easily getting up and down such straight scaffoldings. Wouldn't it make sense to build one that fit the whole length of the biggest car and have it standing in one area, so whenever you need to work on the roof, you park the van next to that scaffolding? Another thing, when working in heights, consider your safety and maybe connect a stair to the scaffolding, so you don't have to climb up the ladder. It will also make it easier on you to bring things up and down. 🙂

As stated before, ALWAYS use stainless on anything outside. Nuts and washers to. Ideally, lockouts with never seize on the threads. Blind holes should get a drop of blue loctite.

George - thanks for this video - curious question - what solar panels are you using in this build?

Great job, thanks for the video. I wanted to get more into 80/20 and I look at it as an adult Tinker Toy. Since you've built this Solar Energy kit for a vehicle roof have you made one for a hybrid car to recharge the battery? I charge my car when I get home as I have solar on our roof and it will get me to work. What I was thinking of doing is designing a detachable solar kit that I could attach to the roof when I get to work and remove it when I get home.. This will allow me to charge my car while I'm at work. Has anyone done this?

Awesome setup! I want to build the same for our Ducato. Can you specify what the measurements are of these panels? I have to try and get the same in europe.!

I've always been against using regular steel hardware in outside/wet conditions. Even zinc or galvanized or other 'anti rust' just doesn't stand up to the rigor. Use stainless A4 or AT grade or go for titanium hardware. BTW I hope you also used stainless nuts and washers, not just bolts.

Use the solar panels as an extending/tilking awning... Slide them off the roof, tilt down, boom. No need for an awning.

Hope that your stainless steel parts are AISI 316 otherwise with AISI 304 you get contact corrosion between stainless steel and aluminum.

This was a very informative video, thanks! I noticed that the AC unit is installed in the front and the Maxxair Fan in the rear on the roof. We are doing our own build, and are discussing the pros and cons of the placement of both units. Do you have a preference?

Have you done your stacked (multi layered) solar system as of yet? Carpe diem and thanks

What kind of solar panels did you put on that van? very interested in finding out. Thanks

PS. with the solar panels covering the whole roof and even shades it to keep the heat off.

What size 15 series do you recommend using for a van roof rack? The regular, lite or ultra lite?

lol right when the first shots started I literally thought, "what kind of bolts is he using on those rails?"

Holy moly, that's a clean looking rooftop. Is it feasible to mount different sized (smaller?) solar panels in-between?

Naive (?) question, but won’t the anodized layer on the 80-20 rapidly oxidize in this extreme outdoor use? Obviously it won’t rust, but corroded, pitted aluminum will weaken the structure and look bad..

Working alone, I know how you feel, I am building my own home alone, a long story.

Hi, great job. You have inspired me to make my own. Can you confirm the size of 80/20 you used. I will also be attaching an awning. Thanks.

I just got my shipment of 8020 for my Ford Transit a couple of days ago and haven't pinned down a good, flat roof to rack mount so I can attach an awning. The one you used looked nice; will you share where you got those?

hi where can i buy those unaka the black you show thanks

Duralac 👍

Where did you get the roof mounting brackets? We are installing an 8020 roof rack as well

It would be so nice if you would include links to the individual products you recommend on the various stages. Thank you...

What series of 8020 did you use here? 4040? 15? Thanks and great video

Now I am concerned about stainless fasteners their shear strength is crap.15 yrs ago stainless was all the rage in the building/construction industry. They strip they snap they are not structural. A better solution will be AQC through galvanized ceramic coated fasteners. Just ordered my 80/20 catalog starting a build this fall. Nice roof rack Sir.

Hey, i saw the work bench behind the one you were working on is sitting on top of what looks like legs that fills away like a beach chair. What brand are those legs?

Hi, is that a 6' scaffold? I'm doing a similar project but with strut channel stuff instead of 8020, but the position you get on your scaffold looks perfect for what I want to do.

Have you ever mounted a 4-way camera system to an 8020 roof rack? I can't find any resources for mounting them.

Got links where you purchased your 8020s and the L brackets that hold it to the van?

I've watched this 3 times and I still am not sure. Are the panels affixed only on the shorter sides, with bolts to the cross bars, or are they also affixed on the long outer edges? I saw you mention the angle and the drilling on the sides, but i cant see where the long edge is affixed on this rack? I am making a rack and my panels are wider than the track. Wondering if I can just affix the short sides of the panels and maybe a beam down the middle. Thank you! My mom and I are the biggest fans!

Have you ever given any thought to designing a solar panel slide-out system? Stack them on top of each other while traveling but when parked you could slide them out from each other. Save room and give you twice as much charging power. Instead of 400 watt, you could have 800 in the same area when stored.

Hello, just a Little question. What’s size aluminium profile ? 30 x 30 ? Thanks so much for all. Very good job !!! From New-Caledonia

OK you are getting closer for what I’ve been trying to tell people for 10 years now. Take that solar rack go up even higher covering the top of the air conditioner, turn the panels longways and hinge on one side and put an air dam on the front to keep air from lifting panels up. The hinge is so you can get up on the roof and do maintenance you can even put hydraulic struts on it to hold him up out of the way. I hope somebody can use it someday. Because you can get solar the whole length of your roof.Or you can combined it like I seen that one van to where they slide out from underneath each other also.

In past builds you used adhesive on the panel mounts to the roof. Did you do same or did you go through the roof with the Unakas.

I updated the bill of material of my dream RV accordingly, thanks to you and your guardian angels!

316 ss is marine grade, you must use something on the threads, locktite or anti-seez, stainless screws with the same stainless nuts have a tendency for galling.

My biggest concern would be noise whistle or hum.

Anybody have any good tips on roof brackets for Ford transit that accommodate the 3% pitch of the roof where mounting plate sits? I want to build my own rack but the roof mount cleats are the hardest thing. Thanks in advance (hopefully;)

Did you use Locktite on your bolt threads, or would it be better to use lock washer?

I shouldered a 75 pd Dometic up a ladder to my high roof transit. One of the more unsafe things I’ve done.

Something I’ve been wondering about solar panels on vans is, how easy is it for someone to steal them and what can be done to prevent this?

Could those bars hold a rooftop tent and 2 people?

I am building a shuttle van with six solar panels on the roof weighing about 20 lbs each over a span of around 20’. Do you think the 10 series 80/20 1”x1” or 1”x2” would be sufficient or would I have to go with the 15 series aluminum?

I’m interested to understand why the panels and awning are mounted so high above the roof and not much lower and closer?

Depends where you’re at but I would always use stainless on exterior hardware. Stainless will still rust and corrode just not as fast. What you want is the nitride treated hardware it won’t fail. I would also powder coat those rails because aluminum will oxidize over time. If you’re by the coast a lot you’re gonna have rust quick on any vehicle though.

George..I have been following you for past 2 years... great work...and u r an inspiration...but bro..I can feel u getting old ...so please add someone to help you out...take care

You've maybe not b seen it but Thule do a smartclamp system for the Promaster.

great video, as always! One question, are you considering the corrosion that occurs between dissimilar metals? You WILL get corrosion between the aluminum and the stainless steel unless they are not in physically touching each other. Less of an issue/concern in invisible areas, but you may want to consider using plastic spacers/washers wherever you don't want visible corrosion after a few months.

I just finished my 8020 roof rack yesterday and then I saw this!! I haven't put it up on my roof yet and I can change out the bolts. Do they have them at Lowe's and what would I look for?

Would be nice without bridgeplates. Here in Germany we can order lengths until 6m of 8020.