(619)949-7564
info@sprintervansolutions.com
7754 Arjons Dr, Ste B, Ca San Diego, 92126
info@sprintervansolutions.com
7754 Arjons Dr, Ste B, Ca San Diego, 92126
LIMITED-TIME 10% OFF FOR NEW CUSTOMERS!
Book your service online before the end and get 10% off for parts. Don’t miss this chance to give your Sprinter expert care at an exclusive discount.
*Discount applies only to new customers booking through the website.
LIMITED-TIME 10% OFF FOR NEW CUSTOMERS!
Book your service online before the end and get 10% off for parts. Don’t miss this chance to give your Sprinter expert care at an exclusive discount.
*Discount applies only to new customers booking through the website.
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SprinterVanSolutions
❄️ From Fan to Freeze: Custom 12V A/C Installation & Roof Rack Modification in San Diego
The Ultimate Upgrade: Swapping Your Sprinter’s Roof Fan for a 12V A/C with Custom Rack Fabrication
December 3, 2025
Living the Van Life in San Diego is a dream, until you hit that mid-August heatwave in El Cajon or head out to the Anza-Borrego desert. Suddenly, that basic roof fan just isn't cutting it. You are moving hot air around, but you aren't actually cooling down.
You know you need an Air Conditioner. But here is the problem many Sprinter owners face: You already have a massive roof rack installed.
Most shops will tell you that you need to buy a completely new rack or that the A/C won't fit. At Sprinter Van Solutions, we don't believe in "can't." We specialize in complex retrofits that involve roof fan removal, aluminum welding, and custom roof rack modification to make everything fit like a glove.
Living the Van Life in San Diego is a dream, until you hit that mid-August heatwave in El Cajon or head out to the Anza-Borrego desert. Suddenly, that basic roof fan just isn't cutting it. You are moving hot air around, but you aren't actually cooling down.
You know you need an Air Conditioner. But here is the problem many Sprinter owners face: You already have a massive roof rack installed.
Most shops will tell you that you need to buy a completely new rack or that the A/C won't fit. At Sprinter Van Solutions, we don't believe in "can't." We specialize in complex retrofits that involve roof fan removal, aluminum welding, and custom roof rack modification to make everything fit like a glove.
The Challenge: Fitting a Square Peg in a Round Hole
Removing a standard roof fan (like a MaxxAir) and replacing it with a powerful 12V A/C unit isn't a simple "plug and play" job.
Our Solution: Precision Cutting & Aluminum Welding
Take a look at the photos of our recent project. This client had a full-length roof rack with a mesh floor. A standard shop might have hacked away at the metal and left sharp edges, or told the client to lose the rack entirely.
We took a surgical approach.
We took a surgical approach.
1. Roof Fan Removal & Prep
First, we carefully removed the existing fan. This is the perfect time to inspect the roof for any corrosion or failed sealant (a common issue on older installs). We clean the surface down to the bare metal if necessary to ensure the new gasket seals perfectly. No leaks allowed.
First, we carefully removed the existing fan. This is the perfect time to inspect the roof for any corrosion or failed sealant (a common issue on older installs). We clean the surface down to the bare metal if necessary to ensure the new gasket seals perfectly. No leaks allowed.
2. Custom Rack Modification
Here is where the magic happens. We measured the exact dimensions of the new 12V A/C unit. Then, we cut the existing roof rack mesh and structural bars to create a custom opening. But we didn't just leave a hole. Using TIG aluminum welding techniques, we fabricated a new custom frame integrated into the rack.
Here is where the magic happens. We measured the exact dimensions of the new 12V A/C unit. Then, we cut the existing roof rack mesh and structural bars to create a custom opening. But we didn't just leave a hole. Using TIG aluminum welding techniques, we fabricated a new custom frame integrated into the rack.
- Strength: We welded new support bars around the opening to restore the structural integrity of the rack.
- Protection: The new frame acts as a guard for the A/C unit.
- Aesthetics: As you can see in the photos, it looks like it came from the factory that way. Clean lines, black powder coat finish, and zero rattling.
3. The 12V A/C Installation
Once the "surgery" on the rack was complete, we installed the new 12V A/C unit. These modern units are game-changers for off-grid travel. Unlike older 110V units that require a generator or shore power, these run directly off your house battery bank, allowing you to stay cool while boondocking.
Why Choose Custom Fabrication Over Buying New?
Why go through the trouble of modifying your current rack?
Once the "surgery" on the rack was complete, we installed the new 12V A/C unit. These modern units are game-changers for off-grid travel. Unlike older 110V units that require a generator or shore power, these run directly off your house battery bank, allowing you to stay cool while boondocking.
Why Choose Custom Fabrication Over Buying New?
Why go through the trouble of modifying your current rack?
- Save Money: High-end roof racks cost thousands of dollars. Modifying yours is a fraction of the price.
- Keep Your Gear: You don't lose your storage space; you just optimize it.
- Perfect Fit: We build the mount to fit your specific A/C unit, ensuring it sits flush and secure.
Frequently Asked Questions (FAQ)
In most cases, yes. Whether it’s aluminum or steel, our San Diego shop is equipped with the welding gear to cut, reinforce, and refinish the metal.
We take extensive precautions. The rack is typically protected or removed if necessary, and we use welding blankets to protect your Sprinter’s roof and solar panels from sparks or heat.
Absolutely. Modern 12V units are incredibly efficient and can easily keep a well-insulated van comfortable, even in the Southern California heat.
Ready to Chill Out?
Don't let a roof rack stand in the way of your comfort. If you want to upgrade from a fan to an A/C but are worried about fitment, bring your van to Sprinter Van Solutions.
We are San Diego’s experts in aluminum welding, fabrication, and electrical upgrades. Let’s build something awesome together.
Contact us:
📍 7754 Arjons Dr, Ste B, San Diego, CA 92126
📞 (619) 949-7564
🌐 sprintervansolutions.com — Book an inspection today.
We are San Diego’s experts in aluminum welding, fabrication, and electrical upgrades. Let’s build something awesome together.
Contact us:
📍 7754 Arjons Dr, Ste B, San Diego, CA 92126
📞 (619) 949-7564
🌐 sprintervansolutions.com — Book an inspection today.
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