Installing a roof rack is one of the most valuable upgrades for your van—especially when it’s the Unaka Explorist.life Edition Roof Rack, a precision-built system made for solar, storage, and rugged travel. In this full guide, we’ll walk through the entire installation process, from roof prep to solar panel mounting, based on a complete real-world install experience.
Why Choose the Unaka Explorist.life Roof Rack?
- Precision fit for the Ford Transit
- 80/20 aluminum rails for modular attachments
- Solar-ready (580W Explorist.life kit compatible)
- Powder-coated and durable with stainless steel hardware
- Low wind noise design with rubberized fairing seal
Tools and Supplies You’ll Need
- Heat gun
- Razor blade and plastic scraper
- Body panel removal tools
- Dremel with grinding bit
- Denatured alcohol
- Permanent marker
- Black RTV sealant
- Lap sealant
- Half-inch wrench and Allen keys
Step 1: Roof Prep and Mount Access
Identify Mount Points
The Ford Transit has eight factory-threaded mounting points on the roof. Use a razor blade to score the paint around the plastic caps, then apply heat to soften the adhesive and gently lift each cap with plastic tools.
Clean and Prep the Surface
Once exposed, clean each hole with denatured alcohol and apply rust preventative around the metal. If the threaded hole is misaligned, carefully use a Dremel to widen the opening.
Step 2: Assemble the Roof Rack Rails
Front vs Rear Rails
The longer 80/20 rails go toward the front, and the shorter ones go toward the back. Use the included hardware to attach the side support plates to each rail.
Measure and Mark Foot Placements
Refer to the PDF guide from Unaka to mark the location of each mounting foot. Use a tape measure and permanent marker to mark exact points before setting anything on the roof.
Step 3: Mount the Rack to the Roof
Apply Sealant and Position the Feet
Use black RTV sealant around each mount hole. Position the rail feet and bolt them into place using the rubber-backed bolts provided. Only fully tighten once everything is aligned and flush.
Pro tip: Hand-tighten during initial fitment and only fully torque down once everything is square.
Step 4: Install the Front Wind Fairing
The wind fairing minimizes wind noise and improves aerodynamics.
Installation Tips
- Slide the side wings into place on the fairing
- Use rubber trim to protect paint and seal air gaps
- Tighten top bolts first to angle the fairing downward
- Compress the gasket fully for a clean, noise-reducing seal
Watch for sharp edges while tightening—gloves recommended!
Step 5: Solar Panel Mounting
Panel Layout
The system is designed for:
- Two 200W panels in the front
- One 155W in the middle
- One smaller panel at the rear, next to the AC unit
Install Method
- Slide T-nuts into the 80/20 rails
- Keep panels loose to allow for wiring and adjustments
- Use a towel to protect the rails during panel placement
- Once aligned, secure each panel with two bolts per side
Unaka’s thoughtful design allows the panel to slide over bolt heads thanks to channel cutouts.
Final Thoughts: A Top-Tier Roof Rack for Van Builds
This was one of the most precise and smooth installs we’ve done. Everything from the pre-drilled brackets to the crossbar fitment felt tailor-made for the Transit.
Why It Stands Out
- Excellent tolerances
- 80/20 channel makes future upgrades easy
- Solar-ready layout with smart cable access
- Minimal wind noise with properly sealed fairing
Pro Installation Tips
- Don’t apply lap sealant until you’ve cut holes for fans or AC to avoid trapping metal shavings
- Use the crossbars without solar panels to square the rack before final tightening
- Leave plastic end caps off until your build is finished so T-nuts can be added as needed
Bonus: Free Van Build Cheat Sheet
Grab our DIY Van Build Cheat Sheet—a searchable list of 250+ tools and components we use for every van build. It’s free and available at VanBuilderHQ.com, or click the link in the video description to download.
Conclusion
The Unaka Explorist.life Roof Rack is one of the best-engineered systems we’ve installed on a Ford Transit. It’s sturdy, solar-ready, modular, and installs with high precision.
Got questions? Drop them in the comments. And don’t forget to check out our three-part livestream series for deeper walkthroughs of each phase.
If you found this helpful, share this guide, subscribe for future DIY content, and don’t forget to download your free build checklist.
Happy building!
