Van Rooftop Tent Bottom Entry DIY

We added a DIY Bottom Entry “pass-through” hole to the Roofnest Rooftop Tent on our Ram ProMaster

This custom DIY bottom entry access hole allows for easy access and egress between the van’s cab and the roof tent. It also allows for communication between occupants of the van and the rooftop tent, as well as allowing for improved ventilation and heating from the van’s parking heater.

Keep Reading To See How We Built A Custom DIY Bottom Entry Access Hole In Our Roofnest Roof Top Tent Mounted On A Ram ProMaster Van

Van Rooftop Tent Bottom Entry DIY

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Possible Uses And Benefits Of Adding Bottom Entry To Our Roofnest Rooftop Tent

We have been using our Roofnest Rooftop Tent on our Ram ProMaster for a while now, and we have had some amazing adventures.  Every time we used the tent I was always thinking of the benefits of having a bottom entry for access from below. Here are some of the benefits we found by having the rooftop tent bottom entry in our Roofnest Falcon XL.

• Communication

The number one reason for modifying our roof tent for the bottom entry is to allow easy communication between the two spaces. Previously, communication between the roof and bottom levels was difficult, we would open the side door to get close enough to talk, but it was not convenient. Having a communication pathway gives peace of mind, the kids can speak to us if there is a problem and we can check in easily without effort.

• Airflow

This one is huge. A common issue people have with rooftop tents is a buildup of condensation and moisture. The anti-condensation mat under the mattress does a little to reduce condensation soaking into the mattress, but there still tends to be a lot of condensation forming and pooling in low spots. Having the bottom access hole allows me to use our Van Roof Vent Fan to force air up into the roof tent. 

• Heat

A Gasoline Parking Heater, be it Webasto, Espar, or one of the Chinese equivalents, is one of the best things you can have in a van. Now we can use our Chinese Webasto copy to heat the roof tent as well. 

• Access

While access and egress are not the primary motivation for undertaking this project, it is hugely beneficial. Now when we are forced to stay inside due to inclement weather conditions, not only can we access the RTT via our Rear Door Ladder, but we also have an option to access the rooftop tent without going outside. 

Modifying Our Roofnest Rooftop Tent To Add Bottom Entry Access Hole In Ram ProMaster Van. 

Design Thinking 

Some Of My Thought Processes And The Many Challenges We Encountered Throughout This Project 

• Hole Location (Van Roof)

The Ram ProMaster features a raised section of the roof panel that is designed for the installation of a refrigerator or AC unit. This area is also flat making it a good place to have the hole located. 

• Hole Location (Roof Top Tent)

When deciding the location of the hole in the tent, we wanted the hole to be as far forward towards the hinge without being too close to cause problems during installation. 

• Access Connector

Our Roof Top Tent sits a small distance above the roof panel. To fill this space we built what we call the access connector. Conveniently, the nominal dimensions of six-inch lumber just happened to be a perfect size. We will build a transition piece to tie the two layers together. 

• Tent Mounting Track Too Narrow. 

The Roofnest Falcon XL has two Aluminum Mounting Track Rails to allow for easy installation on numerous vehicles. This track system is narrower than our hole. These would have to come out to accommodate the new bottom entry hole. 

• Crossbars 

The design of our DIY Aluminum Van Roof Rack allows us to reuse our 2×2 square tube aluminum crossbars. The removal of the Roofnest Rails means the crossbars now hit the tent frame and will not sit flush with the tent floor panel. To fill this gap and make a secure connection, we are adding a piece of aluminum channel to the top of our crossbars. 

• Mattress Modification 

The mattress had to be cut to allow the use of the new bottom entry hole. To make it more functional, I cut the hole piece into three pillows, and one slightly longer size piece. To make it all look clean, I decided to have a new mattress cover made by an upholsterer.

• Van Roof Deck 

Part of this van project is to build a small roof deck to enable easy access to the rooftop tent. We will use lightweight aluminum square tubes for the frame and cedar fence boards for the decking. The decking will be coated with spar urethane to protect it against the elements. We considered using aluminum planks and plastic dock panels but opted for fence panels due to the cost being way cheaper and readily available. 

• Fan Protection 

Having the Maxxair Fan close to the tent door makes it vulnerable to damage from being bumped into. To protect the fan we designed a frame to cover it. The fan can still open as normal, and now we have a nice little tabletop we can use for rooftop chilling. 

Now Let’s Get To The Fun Part –  Installing A Custom Bottom Entry Hole In A Van Mounted Roofnest Roof Top Tent 

The Video

The Tools and Materials 

• Ryobi Sliding Mitre Saw
• Milwaukee 12v Drill Driver
• Drill Bit Set
• Irwin Step Drill Bit
• 90-degree Corner Clamps
• Quick Grip Bar Clamps 
• Milwaukee M12 Pin Nailer 
• Socket and Wrench Set
• 8-inch Try Square
• Hole Saw Set
• Deburring Tool
• Tape Measure
• YardStick Ruler 
• Jigsaw
• Clean Cut Electric Metal Shears 
• Utility Knife 
• Kregg Pocket Screw Jig

 

• 1×6 Pine Lumber
• 2×4 Pine Lumber
• One Step Stain and Polyurethane
• Paint Brushes 
• Abrasive Scouring Pad
• ¼-20 Threaded Wood Inserts
• Swivel Caster Wheels
• ½ Inch Bolts
• Black Spray Paint
• Painters Masking Tape 
• Sikaflex 221
• 1×3/4 Aluminum Channel 
• Sikaflex Construction Sealant 
• Enamel Metal Paint
• Wood Glue 

The How 

How We Built A Custom Bottom Access Entry Hole For Our Roofnest Rooftop Tent In Our Ram ProMaster Conversion Van

Disclaimer! This is how we modified a Roof Top tent for bottom access. DO NOT take this information as professional advice. Do your research and make your own decisions accordingly. 

Step-1 Build Access Connector

The first thing we did was build the Access Connector. Cutting the 1×6 SPF lumber to the appropriate size using our 7-¼ inch Ryobi Sliding Mitre Saw.  We beveled the corner edges to keep the connector within the raised area of the roof panel.

We used 90 Degree Corner Clamps to hold it square before securing it with Glue and Pin Nails. 

Two coats of a One-Step Stain and Polyurethane will seal out any moisture and ensure longevity.  #ProTip: Use Scotchpad between coats for a smooth finish.

The last step of building the access connector was to add threaded inserts around the top side of the connector. These will join the connector to the inside trim.

Step-2 Build Rolling Platform

To make for easy moving while working on the rooftop tent. We built a simple rolling platform using 2x4s and caster wheels. 

Step-3 Remove Factory Roof Top Tent Mount Rails

The Roofnest Factory Mounting Rail System is easy to get off by removing the eight nuts located inside the tent. Once the fasteners were removed we supported the tent with a piece of 2×4 before pulling the rails out.

Step-4  Build And Install New Cross Bars 

Reusing the existing Cross Bars, we added a piece of Aluminum Channel to the top side of the bars. We used bolts to hold them together while being welded. We used a hole saw to drill a large hole in the side and a Deburring tool to clean up any sharp edges. The crossbars are painted with black paint before installation.

We reused the Mounting Rail holes to fasten our new crossbars in place. The large side hole allows us to use a shorter bolt to fasten the cross bars to the bottom panel of the Roofnest. 

Step-5 Cutout Access Hole In Bottom Of Roofnest Rooftop Tent 

I taped out the hole location with masking tape before marking the cut line with a permanent marker. I drilled a starter hole in each corner and then used my jigsaw to cut out the hole. #ProTip We use some tape to stop the off cut from falling and prevent the blade from binding

Step-6 Trim Rooftop Tent Bottom Access Hole With Aluminum Channel 

We used Sikaflex 221 to glue some aluminum channel pieces onto the newly cut edges of the hole. Once the glue had set, we then used Sikaflex Construction Sealant around the edges to fill any gaps.

Step-7  Remove Ceiling Panel 

We designed our ceiling and wall panels to be easy to remove for maintenance. It was as simple as popping out the recessed LED pot lights and undoing a few screws. 

Step-8 Cut Hole In Van Roof

We walled off the work area with some cardboard to prevent metal swarf from migrating across the van roof. Before drilling start holes and using our Metal Shears to cut out the hole. #ProTip We use Clean Cut Electric Metal Shears for the cleanest possible cuts.

Step-9 Deburr And Paint Cut Edge

Removing any sharp edges was easy enough using a Swivel Head Deburring Tool. We scuffed the area before painting the raw metal with enamel rust paint.

Step-10 Install Access Connector 

The Access Connector is glued and screwed in place using Sikaflex 221 and #8×1-½” screws. Once screwed in place, we layered on a thick bead of 221 around the base.

Step-11 Lift Tent On Top Of Van

The moment of truth! Will the holes line up? No doubt it did. 

We used a local trucking company to help us with the lift. No struggling, no stress. The operator lifted it and held it elevated just above the roof while I lined up the holes and bolted it down.

Step-12 Modify And Reinstall The Ceiling Panel

We marked the location of the ceiling panel hole from the top using a straight edge. Once we removed a strip of the thermal barrier, we marked the cut line and used our jigsaw to cut out the hole. The panel is trimmed and stiffened using pieces of poplar, then stained with the same color to match the original piece.

Step-13 Build Access Transition Piece

We had our local wood store rip our materials to the correct size, so we could make all the final cuts using our miter saw. The main structural piece of the transition is glued and screwed together using Kregg Pocket Screws. Then we added the tunnel section followed by the top trim.

Before installing we coated it with two layers of polyurethane stain. The finished piece slots in perfectly making a seamless transition between the tent and the van.

Step-14 Modify Anti-Condensation Mat

The Roofnest Anti Condensation Mat will no longer fit now we have a hole in the bottom of our tent. We need to cut a hole in it. The material is easily cut using a sharp utility knife. We clamped the way to a piece of wood as a backing to protect the knife and as a way to stop the mat from moving while being cut.

Step-15  Modify Mattress 

After removing the mattress cover, we used a sharp utility knife to cut the mattress foam into the required shapes and sizes. Once cut, we dropped the pieces off at a local mattress and upholstery shop to have new custom covers made.

Step-16 Build Van Rooftop Deck

The frame portion of the roof deck is made of 1×1 aluminum square tube. We used long ¼” bolts to hold it together while being welded. Once the frame was built we had it covered with Matt Black Powder Coating.

Next, we cut the cedar fence boards to the correct size and coated them with spar urethane before bolting them in place using stainless machine screws.  #ProTip: Finishing washers not only look good, but they also cover up oversized holes. 

Our Custom Van Bottom Entry Rooftop Tent Modification Is ✅ 

Now that our Roofnest Rooftop Tent custom bottom access modification is complete we can now access the tent without having to climb up and down via the outside of the van. The multiple benefits have made our Rooftop Tent more versatile and comfortable. This project was definitely worth the investment in time and effort!

Share Your Thoughts 

Have you installed or are you planning to install a rooftop tent in your van? Have some knowledge to share? Drop a comment in the box 👇👇

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As always, thank you for taking the time to visit Weekender Van Life. And remember, always take the road less traveled!

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