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Day 101: Electrical Wiring and Devices on Roof – Day 6

An organized electrical conduit system installation on a camper van's roof under the sunny sky.

Projects

  • PVC electrical wire conduit system on roof with junction boxes

Project Status

  • In progress

Time Spent

  • 8 Hours

Steps Taken

  1. Drill holes in passenger front junction box
  2. Install male thread PVC connectors and thread on female PVC connectors acting as nuts
  3. Install wire gland
  4. Cut PVC pipe to size running to large junction box
  5. Use label maker to label wire running into van
  6. Strip wires with stripper
  7. Solder seal wires together with heat gun
  8. Run wires through junction box and PVC pipe and into van at large junction box
  9. Connect junction box and PVC pipe and apply PVC cement

Materials Used

  • Keep in mind that prices frequently fluctuate.
  • It’s common for products to be delisted on Amazon. If you find a delisted product, please Email Me at steve@campervanfreedom.com and I will fix it.
REOLINK IP Security Camera Outdoor, 5 MP Home Surveillance Outdoor Indoor PoE Camera

REOLINK IP Security Camera Outdoor, 5 MP Home Surveillance Outdoor Indoor PoE Camera

$54.99
San-Young LED Tractor Work Lights 4 Inch LED Pod Lights 120W 10000lm 12V 24V Truck ATV UTV RV RZR Boat Pickup Golf Cart Snowblower Jeep Square LED Offroad Driving Working Spot Lights, 10Pack

San-Young LED Tractor Work Lights 4 Inch LED Pod Lights 120W 10000lm 12V

$69.99
Sealproof 1-Gang 3 1/2-Inch Holes Weatherproof Rectangular Exterior Electrical Outlet Box with 3 Outlet Holes, Three 1/2" Holes, Single Gang, UL Listed

Sealproof 1-Gang 3 1/2-Inch Holes Weatherproof Rectangular Exterior Electrical Outlet Box

$7.29
Sigma Engineered Solutions, Gray 14240 1-Gang Rectangular Stamped Weatherproof Cover, 1 Count (Pack of 1)

Sigma Engineered Solutions, Gray 14240 1-Gang Rectangular Stamped Weatherproof Cover

$1.48
MAKERELE Cord Grip Cable Glands Kit for Electrical Box NPT Waterproof Nylon Strain Relief 1/4” 3/8” 1/2” 3/4” 1” 1-1/4” 50pcs Junction case Connector Black With Gaskets

MAKERELE Cord Grip Cable Glands Kit for Electrical Box NPT Waterproof Nylon Strain Relief 1/4” 3/8” 1/2” 3/4” 1” 1-1/4” 50pcs Junction case Connector Black With Gaskets

$27.11
TICONN 150 PCS Solder Seal Wire Connectors, Heat Shrink Butt Connectors, Waterproof and Insulated Electrical Wire Terminals, Butt Splice (150PCS)

TICONN 150 PCS Solder Seal Wire Connectors, Heat Shrink Butt Connectors, Waterproof and Insulated Electrical Wire Terminals, Butt Splice (150PCS)

$9.89
GS Power 12 Gauge Stranded Flexible Copper Clad Aluminum CCA Primary Automotive Wire for Car Stereo Amplifier 12Volt Trailer Harness Hookup Wiring. 50 ft Red & 50 feet Black

GS Power 12 Gauge Stranded Flexible Copper Clad Aluminum CCA Primary Automotive Wire

$17.49
Jadaol Cat 6 Ethernet Cable 50 ft, Outdoor&Indoor 10Gbps Support Cat8 Cat7 Network, Flat High Speed RJ45 Internet LAN Computer Solid Patch

Jadaol Cat 6 Ethernet Cable 50 ft

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$12.34
letsFix 3/4" PVC Pipe, DIY PVC Projects for the Home, Garden, Greenhouse, Farm and Workshop, Sch. 40 Furniture Grade, White [40" x 10 Pack]

3/4″ PVC Pipe [40″ x 10 Pack]

$49.99
10pcs 3/4 Inch White 2-Way PVC Male Adapter Pipe Fittings (Socket x Male Pipe Thread) Coupling with 3/4-Inch Male Thread Schedule 40-10 Pack (0.75 Inch)

3/4 Inch White 2-Way PVC Male Adapter Pipe Fittings

$12.99
3/4" 45 Degree PVC Elbow Fitting, Furniture Grade 2 Way Right Angle Elbow Side Outlet, PVC Corner Fittings for DIY Building Furniture Greenhouse Shed Pipe Fittings Tent Connection (Pack of 8)

3/4″ 45 Degree PVC Elbow Fitting

$11.99
Fitvell 3/4" PVC Pipe Fitting Adapter Connector Union Coupling Schedule 40 (Slip Socket x NPT Female Pipe Thread), Pack of 10

3/4″ PVC Pipe Fitting Adapter Connector Union Coupling

$12.90
Stainless Steel Cable Tie Gun With 100PCS Stainless Steel Cable Ties Cable Tie Tool for Metal Cable Zip Ties Tensioning Cutter Metal Zip Tie Tool Kit Self-Locking Zip Ties Kit

Stainless Steel Cable Tie Gun With 100PCS Stainless Steel Cable Ties

$27.59
11.8 Inch Metal Zip Tie (With Screw Hole Base), Multi-Purpose Heavy-Duty Stainless Steel Zip Tie With Uv Resistance, Suitable For Outdoor Fixing Of Pipes, Machinery, Wire Mesh, Fences, Etc.

11.8 Inch Metal Zip Tie (With Screw Hole Base)

$16.99
Oatey-31012, 4 oz, Clear PVC Cement

Oatey-31012, 4 oz, Clear PVC Cement

$9.46
GE Advanced Silicone Caulk for Kitchen & Bathroom - 100% Waterproof Silicone Sealant, 5X Stronger Adhesion, Shrink & Crack Proof - 10 oz Cartridge, Clear, Pack of 1

GE Advanced Silicone Caulk

$10.77
Amazon Basics Electrical Tape, 3/4-inch by 60-feet, BLack, 6-Pack, Model: DS-TPAMZ013 (Previously AmazonCommercial brand)

Amazon Basics Electrical Tape, 3/4-inch by 60-feet

$11.59
Junction Box IP65 Waterproof ABS Plastic Electrical Project Case Power Junction Boxes, Project Box with 4 PCS M16 Cable Glands 11.42x8.27x3.94 inch (290 x 210 x100 mm)

Junction Box IP65 Waterproof 11.42×8.27×3.94 inch

$29.99

Tools Used

Dewalt DCD794B 20V MAX ATOMIC COMPACT SERIES Brushless Lithium-Ion 1/2 in. Cordless Drill Driver (Tool Only)

Dewalt DCD794B 20V MAX ATOMIC COMPACT SERIES Brushless Lithium-Ion 1/2 in. Cordless Drill Driver

Our shortest 20V MAX Drill Driver at 5.88 in. (tool head length only) to access hard to reach areas
$89.79
DEWALT Titanium Nitride Coated Drill Bit Set, Pilot Point, 21-Piece (DW1361)

DEWALT Titanium Nitride Coated Drill Bit Set, Pilot Point, 21-Piece

DEWALT drill bit set has connectable accessory storage system to optimize storage space
$26.14
2pack 60v 9.0Ah Replace for Dewalt 20V/60V Li-Ion Battery DCB609 DCB606 DCB612 DCB206 DCB205 DCB200 Compatible with DeWalt 20V 60V Power Tools

9.0Ah Replacement for Dewalt 20v/60v Max Battery

$29.99
DEWALT 20V MAX Cordless Impact Driver Kit, Brushless, 1/4" Hex Chuck, 2 Batteries and Charger (DCF787C2)

DEWALT 20V MAX Cordless Impact Driver Kit, Brushless, 1/4″ Hex Chuck, 2 Batteries and Charger (DCF787C2)

Brushless motor for efficient performance and runtime
$124.96
NEIKO 10048A Security Bit Set 100-Piece Set Cr-V Steel 1/4-inch Adapters Phillips Slotted Hex Torx Star Tamperproof Pozi Square Spanner Torque Tri-Wing Clutch Spline Wing Nut, Security Torx Bit Set

NEIKO 10048A Security Bit Set 100-Piece Set

These bits are made of a high-quality chrome vanadium steel for strong hardness that can withstand more torque, reduce wear-outs, ensure longevity, and durability!
$15.99
DEWALT DWHT70263M Ergonomic Push Button Locking Folding Metric Hex Key Set

DEWALT DWHT70263M Ergonomic Push Button Locking Folding Metric Hex Key Set

Push-button locking feature locks in three positions at 90°, 135°, and 180°
$12.97
DEWALT DCG412B 20V MAX* Lithium Ion 4-1/2” grinder

DEWALT DCG412B 20V MAX* Lithium Ion 4-1/2” grinder

$99
DEWALT – DW8062 – 10,PK DW8062 4-1/2″x.045″x7/8″ Metal Angle Grinder Thin Cutoff Wheel, 10 Pack

DEWALT – DW8062 – 10,PK DW8062 4-1/2″x.045″x7/8″ Metal Angle Grinder Thin Cutoff Wheel, 10 Pack

$19.75
Milwaukee 49-22-4185 All Purpose Professional Ice Hardened Hole Saw Kit 28 Piece

Milwaukee 49-22-4185 All Purpose Professional Ice Hardened Hole Saw Kit 28 Piece

$191.99
DOWELL 10-22 AWG Wire Stripper Cutter Wire Stripping Tool And Multi-Function Hand Tool，Professional Handle Design And Refined Craftsmanship.

DOWELL 10-22 AWG Wire Stripper

$6.99

Pictures

junction box with PVC connectors and conduit system, wire gland, and electrical wires on camper van roof
junction box with PVC connectors and conduit system, wire gland, and electrical wires on camper van roof
junction box with PVC connectors and conduit system, wire gland, and electrical wires on camper van roof
junction box with PVC connectors and conduit system, wire gland, and electrical wires on camper van roof
PVC conduit system and aluminum extrusion on camper van roof
PVC conduit system and aluminum extrusion on camper van roof
PVC conduit system and aluminum extrusion on camper van roof
PVC conduit system and aluminum extrusion on camper van roof
PVC conduit system and aluminum extrusion and metal zip ties on camper van roof
PVC conduit system and aluminum extrusion and metal zip ties on camper van roof
PVC conduit system and aluminum extrusion and security camera mounting system on camper van roof
PVC conduit system and aluminum extrusion and security camera mounting system on camper van roof
PVC conduit system and aluminum extrusion and security camera mounting system on camper van roof
PVC conduit system and aluminum extrusion and security camera mounting system on camper van roof
Junction box with PVC connectors and wire glands for DIY camper van on van roof
Junction box with PVC connectors and wire glands for DIY camper van on van roof
Junction box with PVC connectors and wire glands for DIY camper van on van roof
Junction box with PVC connectors and wire glands for DIY camper van on van roof
PVC cement
PVC cement

Short Video

Plans For Tomorrow

  • Continue work on PVC conduit system and running wires

Long-Form Article

Project Overview

Today marked the sixth day of the challenging yet rewarding project of setting up an electrical conduit system on the roof of my Ford Transit 250 High Roof Extended van. This system is designed to ensure that all electrical wiring is safely secured and weatherproof, essential for my off-grid living setup.

Project Details

  • Project Type: PVC Electrical Wire Conduit System Installation
  • Current Status: In Progress
  • Hours Spent Today: 8
Close-up view of a weatherproof junction box with intricate wiring on a camper van roof, set against the desert backdrop of Phoenix, AZ.

Work Accomplished

Setting Up the Conduit System

  1. Preparation:
    • Drilled holes in the front passenger junction box.
    • Installed male thread PVC connectors and secured them using female PVC connectors.
  2. Assembly:
    • Attached a wire gland for additional security and protection.
    • Measured and cut PVC pipe to fit the run to a larger junction box.
    • Utilized a label maker to clearly label the wire heading into the van.
  3. Wiring:
    • Stripped the wires using a specialized stripper tool.
    • Solder sealed the wires together using a heat gun for a durable bond.
    • Ran the wires through the junction box and PVC pipe into the van.
  4. Sealing and Securing:
    • Connected the junction box and PVC pipe.
    • Applied PVC cement to ensure a secure and waterproof connection.

Materials Used

  • Electrical Components:
    • REOLINK IP Security Camera, San-Young LED Work Lights, Sealproof Weatherproof Outlet Box, Sigma Weatherproof Cover, MAKERELE Cable Glands Kit, TICONN Solder Seal Wire Connectors, GS Power Automotive Wire, Jadaol Cat 6 Ethernet Cable, and various PVC piping components.
  • Tools for Installation:
    • Dewalt Drill Driver, Dewalt Drill Bit Set, Replacement Battery for Dewalt, Dewalt Cordless Impact Driver Kit, NEIKO Security Bit Set, Dewalt Folding Metric Hex Key Set, Dewalt Grinder, Milwaukee Hole Saw Kit, DOWELL Wire Stripper.
A variety of electrical installation tools and materials laid out inside a camper van, showcasing a neatly organized DIY workspace during the conversion process.

Plans for Tomorrow

  • Continue enhancing the PVC conduit system.
  • Ensure all connections are secure and test the setup for functionality.

Reflections and Considerations

Today’s progress is a testament to the meticulous planning and execution required in converting a van into a livable, functional camper. Each step brings me closer to achieving a self-sufficient lifestyle, encapsulating the essence of Project Freedom. For those following this journey, remember that persistence and attention to detail are key in any DIY project.

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