My house is finished, and we have an electrical box in the ceiling of a bedroom where I am hoping to install a ceiling fan. Upon inspection I'm pretty confident the existing plastic box is not a fan rated box; however it is fastened to the bottom chord of the adjacent scissor truss. It is possible to access the crawl space above, but it would be difficult to get to from access point and would require disturbing the 12"+ of blow in fiberglass along the entire length.
An idea that my dad has is to install a fan rated pancake box (Saf-T-Pan or similar) screwed directly into the truss, and to connect the fan to this box, and leave the existing non-rated fan box in place. Depending on the amount of excess wire I would either pig tail in the existing box or if enough length is available could make connections in the pan box.
Due to the vaulted ceiling I will need to utilize a downrod for the fan to ensure it clears the ceiling, and it will be visible.
Questions I have:
1) Does my Dad's plan seem okay?
a) If okay are there any pitfalls to watch out for?
2) Will I need to remove drywall to keep the pancake box flush with the drywall? Or is it easy to get a fan base cover that would extend over a pan cake mounted to the surface of the drywall.
Appreciate any help/thoughts!