How to Cut a Hole in Your Campervan Roof for a Stove Flue

Cutting a hole in the roof of your campervan can feel like a big moment in any van build. It’s usually the step people worry about the most, but with a bit of planning and the right tools it’s actually very straightforward.

Once the position of your flue has been marked correctly, the next step is creating the opening in the roof so the flue pipe can pass through safely.

Double check the position first

Before cutting anything, take a few minutes to check the position again from both inside and outside the van.

Make sure the flue pipe will run straight upwards and that it won’t interfere with roof ribs, wiring, cupboards or other parts of your build.

It’s always worth checking twice before making the cut.

Mark the circle for the flue

Using the centre point you marked earlier, draw the outline of the hole that needs to be cut.

This will normally be slightly larger than the flue pipe itself to allow room for the flashing or roof boot that seals the flue to the roof.

Taking time to mark a neat circle will make the cutting process much easier.

Tools you can use

There are a few tools that people commonly use when cutting the flue hole.

A hole saw can work very well if you have one large enough for the flue size. This creates a clean and perfectly round hole in one go.

However, many van builders simply use a jigsaw with a metal blade, which works perfectly well on a steel van roof.

Start by drilling a small pilot hole so the jigsaw blade can enter the metal. Then slowly follow the marked circle.

If your van has an internal wooden ceiling you may need to switch to a wood blade for that layer.

Take your time when cutting

The key is to cut slowly and carefully.

Rushing can cause the blade to jump or leave rough edges. Steady cutting will give you a much neater result and make installing the roof flashing easier.

Clean the edges

Once the hole has been cut, the edges should be cleaned up before installing the flue system.

Remove any sharp edges or burrs and make sure the opening is smooth. This helps prevent damage to the roof seal and makes installation easier. Put a little paint on also to protect the metal edges from rusting!

Installing the roof flashing

After the hole has been cut, the roof flashing or silicone boot can be installed.

This seals the flue pipe to the roof and prevents water entering the van. The flashing is normally fixed with screws and sealed with a suitable high temperature sealant.

Once this is fitted, the twin wall flue pipe can pass safely through the roof and connect to the rest of the chimney system.

Take your time and enjoy the process

Cutting the roof is often the step people worry about most, but once it’s done the rest of the installation usually comes together quickly.

With careful planning and steady cutting, it’s a job that many van builders complete successfully themselves.

Need help planning your installation?

If you’re unsure about any part of installing your stove or flue system, feel free to get in touch.

We’re always happy to help and answer questions about installing stoves in campervans and small spaces.