Wherever We Land

Okay, van life dreamers, let me tell you a story – a story of high hopes, sticky sealant, and a persistent, infuriating leak.  It all started so well. I finally bit the bullet and installed a MaxxFan in my Dodge ProMaster.  Ah, fresh air, temperature control, the end of condensation woes! I could practically feel the cool breeze already.

I was meticulous. I watched every YouTube video, read every forum post.  Everyone stressed the importance of sealing.  So, I went for it. I bought not one, but two tubes of SikaFlex NP1.  I laid it on thick.  I mean, really thick.  I wanted to make absolutely sure no water was getting in.  I practically troweled the stuff on, covering the entire base of the fan with a generous, overflowing bead.  I was so confident, I even bragged to my friends about my “watertight masterpiece.”

Famous last words, right?

The first rainstorm proved me wrong.  A slow, but steady drip, drip, drip right inside my van.  My heart sank.  Where was it coming from?  After some careful inspection, I’m 99% sure it’s coming from one of the screws holding the fan base to the roof.  How?!  I slathered that thing in sealant!  It should be entombed in SikaFlex!

Now I’m facing a sticky, frustrating dilemma.  I’m convinced I need to remove the fan and start from scratch.  But how?  That much SikaFlex is like concrete.  I’m picturing an epic battle involving putty knives, solvents, and possibly a small jackhammer.  Okay, maybe not a jackhammer, but you get the idea.

So, I’m reaching out to the van dwelling community, my fellow DIYers, anyone who’s ever wrestled with SikaFlex and lost (or won!).  Have you been here?  Have you conquered the dreaded sealant blob?  Any suggestions for removing the fan without damaging my roof or myself?

Do I try to cut through the sealant with a razor blade?  Will heat help soften it?  Is there some magical solvent that dissolves SikaFlex without dissolving my van?  I’m open to any and all ideas.
I’m also wondering if I should have done something differently in the first place.  Did I use too much sealant?  Was there a better way to seal around the screws?  Should I have used a different product altogether?

Right now, my dream of breezy van life is on hold, replaced by the reality of a leaky roof and a mountain of sealant.  Help me, van gods!  Share your wisdom!  I’m desperate to get this fixed and get back on the road (and out of the rain!).