
Building Your Dream Van: My Love-Hate Journey with 8020 Roof Racks
The Short Version (Because I Know You’re Eager to Start)
Look, I get it – you want to know if this project is worth your time. After three years of living with my 8020 roof rack setup, here’s the truth: It’s not the cheapest option (expect $400-800), and you’ll probably spend a weekend cursing at aluminum rails. But it’s the most versatile system I’ve found, and I’ve never regretted choosing it over pre-made racks. Plus, it’ll handle everything from your Starlink dish to that rooftop tent you’ve been eyeing.
This post covers:
- The Short Version (Because I Know You’re Eager to Start)
- How I Stumbled Into the World of 8020
- The Real Talk About 8020 Systems
- The Good Stuff
- The Not-So-Good Stuff
- The “I Wish Someone Had Told Me This” Parts
- Getting Started
- The Shopping List
- The Build: Real Stories, Real Lessons
- Day One: The Planning Phase
- The Installation Saga
- Real Life With an 8020 Rack
- The Starlink Saga
- Solar Setup: A Love Story
- Community Gold: Real Stories from Fellow Van Lifers
- Sarah’s Story
- Mike’s Journey
- The Nitty Gritty Maintenance Stuff
- The Money Talk
- Looking Back: Three Years Later
- Parting Thoughts
How I Stumbled Into the World of 8020
Picture this: It’s 2021, and I’m standing in my driveway, staring at my newly purchased van, watching water drip through my expensive commercial roof rack after a spring shower. $2,000 down the drain (literally), and I couldn’t even mount my solar panels the way I wanted. That’s when my neighbor Tom wandered over, beer in hand, and changed everything with four simple words: “Ever heard of 8020?”
I hadn’t, and honestly, the name sounded more like a diet plan than a roof rack solution. But that conversation led me down a rabbit hole that completely transformed my van build journey.
The Real Talk About 8020 Systems
Let me be brutally honest about what you’re getting into:
The Good Stuff
- It’s like adult LEGO® for your van (but don’t tell my kids I compared it to toys)
- You can change your mind 50 times about the setup (ask me how I know)
- Strong enough to handle that outdoor shower setup you’re dreaming about
- Costs less than commercial systems (unless you’re like me and keep “upgrading”)
The Not-So-Good Stuff
- You’ll need to embrace your inner perfectionist
- The first time you cut an expensive piece too short is… memorable
- Your significant other might get tired of hearing about T-slots
The “I Wish Someone Had Told Me This” Parts
Getting Started
Remember when I said this was like LEGO®? Well, imagine if LEGO® pieces came in 20-foot lengths and required a saw. Here’s what you really need:
- Basic tools (nothing fancy, I promise)
- A friend (bribe them with pizza)
- Patience (maybe more than one pizza)
- A level (trust me on this one)
The Shopping List
Here’s what actually worked for me after three different iterations:
- Main Rails: 8020 1530-LS
- Think of these as the backbone of your system
- Yes, they’re expensive. No, don’t try to cheap out here
- Cross Members: 8020 1515-LS
- The ribs of your setup
- Buy extra – you’ll thank me later
- All the Little Things:
- Corner brackets (more than you think you need)
- T-nuts (then double that number)
- End caps (because tetanus shots aren’t fun)
- Weather sealing (because rain finds a way)
The Build: Real Stories, Real Lessons
Day One: The Planning Phase
I spent three hours just staring at my van’s roof. My wife thought I’d lost it. But here’s why this matters: every van’s roof has its quirks. Mine had this weird curve that nearly derailed the whole project until I figured out the right mounting strategy.
The Installation Saga
Remember that friend you bribed with pizza? This is where they earn it. Here’s how my installation actually went:
- Measuring Everything
- Measured three times
- Still cut one piece wrong
- Learned some new swear words
- The First Mount Pro tip: Start late afternoon so your neighbors can watch you do the “hot metal dance” in full sun
- The “Oh Wait” Moments
- Realizing the drill battery is dead
- Finding out the hardware store closes in 20 minutes
- Discovering you need just ONE more bracket
Real Life With an 8020 Rack
The Starlink Saga
When I decided to add Starlink, I thought it would be a quick weekend project. Three weekends later, I had finally figured out the perfect mount setup. But here’s the thing – with any other rack system, I would’ve been stuck with a permanent solution. With 8020, I’ve already modified it twice as Starlink’s hardware evolved.
Solar Setup: A Love Story
My solar panel layout has changed four times:
- The “I think this will work” layout
- The “Actually, this would be better” layout
- The “Now I need more power” layout
- The “Final” layout (we all know it’s not final)
Community Gold: Real Stories from Fellow Van Lifers
Sarah’s Story
“I was at a campsite in Moab when my neighbor needed to mount a new antenna. We had his whole system reconfigured in an hour using just the spare parts I had in my van. Try that with a traditional rack!”
Mike’s Journey
“Started with just a basic setup for my mountain bikes. Two years later, I’m running a full solar system, outdoor shower, and retractable awning. Same rack, just evolved with my needs.”
The Nitty Gritty Maintenance Stuff
Look, I’m not great at regular maintenance (my mom’s still reminding me to change my oil), but here’s what actually needs attention:
Monthly-ish:
- Check the obvious stuff (loose bolts, weird noises)
- Look for water where it shouldn’t be
- Listen for new rattles (they’re trying to tell you something)
Seasonally:
- Give everything a good shake
- Check seals before rainy season
- Tighten what needs tightening
- Clean when motivated (or when partner insists)
The Money Talk
Let’s be real about costs:
Basic Setup:
- Materials: $400-600
- Tools you’ll buy but tell yourself you needed anyway: $100-200
- Pizza for helpers: $50
- Satisfaction of building it yourself: Allegedly priceless
Looking Back: Three Years Later
Would I do it all again? Absolutely. Would I do some things differently? You bet. Here’s what I’ve learned:
- Start simpler than you think you need
- Make friends with other van lifers (they have the best tips)
- Keep spare parts (they’re like good karma in aluminum form)
- Document everything (future you will be grateful)
Parting Thoughts
This journey has been about more than just building a roof rack. It’s about creating something that grows with you, about problem-solving on the road, and about the amazing community you become part of.
Is an 8020 roof rack perfect? Nope. But neither is van life, and that’s what makes both so interesting. It’s about the journey, the stories you’ll tell, and the freedom to change your mind without starting from scratch.
So here’s to the adventures ahead, the problems you’ll solve, and the satisfaction of building something that’s uniquely yours. May your cuts be straight, your bolts stay tight, and your adventures be endless.
Happy building, fellow wanderers!
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