Installing a roof rack on your van isn’t just about utility — it’s about maximizing space, function, and style. In this detailed guide, we walk through the step-by-step installation of the new version of the Flatline Van Co Roof Rack on a 2020 Ford Transit Mid-Roof. Whether you’re gearing up for solar panels, fans, or cargo, this updated roof rack design offers improved features and user-friendly installation for DIY van builders.
What’s New in the Flatline Van Co Roof Rack System?
This new version features:
Redesigned low-profile brackets with adhesive backing for easy mounting
Angled design to match the van’s curvature
Flexible front faring to reduce wind noise and improve aerodynamics
Improved sealing components for better weather resistance
What’s in the Box?
The Flatline Van Co roof rack arrives in two separate boxes:
Box 1: Side rails, brackets, faring, and hardware kit
Box 2: 80/20-style aluminum crossbars
Key components include:
- Automotive trim gasket (prevents faring from rubbing against the van)
- Redesigned bracket set (lower profile with adhesive pads)
- Connection plates to secure both side rails
- Flexible faring with dual-finish surface (matte and glossy)
- Complete hardware kit with screws, washers, and tools
Step-by-Step Roof Rack Installation
Step 1: Prep the Van Roof
Use a heat gun to warm the adhesive caps on roof holes.
Remove caps using Goo Gone and clean the surface with denatured alcohol.
Inspect each threaded insert — some may require slight grinding for bolt alignment.
Step 2: Install Mounting Brackets
Apply a thin bead of Dyflex Ultra Sealant to the underside of each bracket and screw head.
Use blue Loctite 242 on each bolt to secure them.
Tighten until the rubber washers begin to compress — don’t overtighten, which can crack the rubber and compromise the seal.
Step 3: Add the Side Rails
Lightly bolt down the passenger and driver-side rails.
Do not fully tighten until all crossbars are installed to allow for alignment.
Pro Tip: Leave the rails slightly loose to allow perpendicular alignment when crossbars are inserted.
Step 4: Insert Crossbars
Begin from the front and work toward the rear.
Use a rag trick to slide bars across the roof without scratching the van.
Keep crossbars loose until they’re all aligned, then tighten.
Installing the New Front Faring
Faring Improvements:
- Made of a flexible, wind-noise-reducing material
- Includes automotive-grade weather stripping
- Better contoured to the van’s profile
Installation Process:
Pre-assemble the brackets to the faring before mounting on the van.
Keep the faring-to-rail connection loose to allow alignment during final mounting.
Secure from center outward, adjusting the pitch to hug the roof curve.
Use included T-slot nuts, black screws, and lock washers to finish mounting.
Adjustment Tips and Pro Recommendations
Do not tighten side rails to the van roof fully until your layout is finalized.
Crossbar adjustability is critical for solar panels and fan placement.
Use the adjustable mounting slots for flexible component layout.
Ideal Dimensions for Solar Panel Layout
For Ford Transit Mid-Roof (148″):
Middle section: ~38” L x 54” W (fits a 175W Renogy panel perfectly)
Front section: ~22.5” L x 54” W
Rear section (optional): Use the additional included crossbar
Optional brands like Zamp Solar offer longer, slimmer panels for side installation, though they tend to be costlier.
Final Thoughts: DIY-Friendly and Flexible
Installing the Flatline Van Co Roof Rack (new version) is approachable for most DIY van builders and can be completed in a day. With thoughtful bracket engineering, built-in adjustability, and a stylish, noise-reducing faring, it’s a solid upgrade for your Transit.
Key Takeaways:
- Leave side rails and crossbars loose until final alignment
- Use high-quality sealant and Loctite for long-term durability
- Plan your solar and fan layout before locking in crossbars
Stay Tuned
We’ll be publishing a step-by-step solar panel install next. If you have any questions, drop them in the comments — we’re happy to turn them into future videos or blog posts!
