This entry records five hours spent mounting the 54-inch Nilight light bar on the van's Flatline roof rack. I added a 2020 aluminum-extrusion beam above the existing rack extrusion, made three connecting brackets and bolted the bar to the new beam.
The mounting was completed during the Light Bar Mounting session. Power-wire work appears in Roof Wiring and Devices Project Day 1. Use this page for the mounting notes, photographs and products from the build.
See The Materials Used See The Tools Used
Projects
- Installing 54" LED Light Bar
Project Status
- Mounting Completed
Time Spent
- 5 Hours
Steps Taken
- Cut 2020 aluminum extrusion with miter saw to 58" to place on top of existing 80/20 extrusion that is part of Flatline roof rack
- Cut three (3) 1.75" aluminum mounts with miter saw for connecting 2020 extrusion to 80/20 extrusion
- Drill two holes in each aluminum mount 1" apart for mounting to extrusion
- Mount extrusion together with aluminum mounts
- 80/20 mount: 1/4-20 bolts, lock washer, flat washer
- 2020 mount: M5 bolts
- Mount LED light bar with 1/4-20 bolts and flat washer to 2020 extrusion
- Thread Locker was used on all bolts
Plans For Tomorrow
- Begin installation of solar panels and roof vent fan
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.
Transit Van Low Pro Roof Rack | 148" High Roof Extended
Nilight - 71017C-A 54" 312W Curved LED Work Light Spot Flood Combo Led Light Bar Driving Light Fog Lamp off road led lights ,2 Years Warranty
This curved LED light bar combines spot and flood illumination in a wide auxiliary fixture. It can provide camper-van work-area or off-road lighting where the mounting, electrical supply and permitted use are suitable.
View On Amazon: Nilight - 71017C-A 54" 312W Curved LED Work Light Spot Flood Combo Led Light Bar Driving Light Fog Lamp off road led lights ,2 Years Warranty
IXGNIJ 10pcs 2000mm T Slot 2020 Aluminum Extrusion European Standard Anodized Linear Rail for 3D Printer Parts and CNC DIY Black(78.7'')
These anodized aluminum profiles provide modular rails for compatible T-slot assemblies. They can form part of a camper-van storage or furniture framework when the connections and loads are designed for the intended use.
View On Amazon: IXGNIJ 10pcs 2000mm T Slot 2020 Aluminum Extrusion European Standard Anodized Linear Rail for 3D Printer Parts and CNC DIY Black(78.7'')
Rrina 180Pcs M5 T-Nuts Screws Assortment Kit, Hammer Head T-Slot Nut for 2020 Series European Standard Aluminum Profile
This assortment provides M5 nuts and screws for slotted aluminum profiles. The hardware forms attachment points for brackets and frame components.
View On Amazon: Rrina 180Pcs M5 T-Nuts Screws Assortment Kit, Hammer Head T-Slot Nut for 2020 Series European Standard Aluminum Profile
Quarter-Twenty Button-Head Bolts
These machine screws have a rounded button head with a hex-socket drive. Their threaded shanks attach parts through matching nuts or threaded holes.
View On Amazon: Quarter-Twenty Button-Head Bolts
Small Parts 18-8 Stainless Steel Flat Washer, Plain Finish, Meets ANSI B18.22.1, 1/4" Hole Size, 5/16" ID, 3/4" OD, 0.065" Nominal Thickness (Pack of 100)
These flat washers distribute a fastener load over the surrounding surface. They sit between a screw head or nut and the part being fastened.
View On Amazon: Small Parts 18-8 Stainless Steel Flat Washer, Plain Finish, Meets ANSI B18.22.1, 1/4" Hole Size, 5/16" ID, 3/4" OD, 0.065" Nominal Thickness (Pack of 100)
The Hillman Group 300018 1/4" Split Lock Washer, Steel, 100 Pieces
These quarter-inch split washers are listed for matching hardware assemblies. They may be useful when servicing van fittings that specify this size and washer type.
View On Amazon: The Hillman Group 300018 1/4" Split Lock Washer, Steel, 100 Pieces
Medium Strength Thread Locker 243, Locktight & Seal Nuts, Bolts, Fasteners and Metals, Blue Threadlocker Against Losening and Leakage(50ml) (50)
This medium-strength threadlocker is intended to help retain threaded fasteners. It could be used on suitable camper-van hardware when the component instructions allow that type of compound.
View On Amazon: Medium Strength Thread Locker 243, Locktight & Seal Nuts, Bolts, Fasteners and Metals, Blue Threadlocker Against Losening and Leakage(50ml) (50)
M5 Flat Washer, 18-8 (304) Stainless Steel Washers Flat, 100PCS
These M5 flat washers spread pressure beneath compatible fastener heads or nuts. They can support small camper-van hardware assemblies where the dimensions and material are suitable.
View On Amazon: M5 Flat Washer, 18-8 (304) Stainless Steel Washers Flat, 100PCS
12 Pieces Square Aluminum Flat Bar, 1/8" Thickness X 1.2" Width X 12" Length Square Aluminum Bar, 6061 Aluminum Flat Plate, 3mm X 30mm X 305mm T6511 Solid New Mill Stock
These aluminum flat bars provide stock for small custom brackets and mounting pieces. Their flat sections can be cut and drilled during fabrication.
View On Amazon: 12 Pieces Square Aluminum Flat Bar, 1/8" Thickness X 1.2" Width X 12" Length Square Aluminum Bar, 6061 Aluminum Flat Plate, 3mm X 30mm X 305mm T6511 Solid New Mill Stock
Slide-In Quarter-Twenty T-Nuts
These slide-in T-nuts provide threaded attachment points within an extrusion slot. A matching bolt fastens a bracket or accessory to the profile.
View On Amazon: Slide-In Quarter-Twenty T-NutsTools Used
DEWALT DCD794B Compact Drill/Driver
This compact cordless drill/driver holds drilling and driving accessories in its chuck. Its brushless motor and short body provide a handheld tool for drilling and fastening jobs.
View On Amazon: DEWALT DCD794B Compact Drill/Driver
DEWALT DW1361 titanium pilot-point drill set, 21 pieces
This drill-bit set covers a range of hole sizes for compatible camper fabrication materials. Select the bit, speed and cutting method for each material and inspect concealed areas before drilling.
View On Amazon: DEWALT DW1361 titanium pilot-point drill set, 21 pieces
Moticett Replacement Tool Batteries
These rechargeable replacement batteries store power for cordless tools. Their removable packs connect at the tool’s battery interface.
View On Amazon: Moticett Replacement Tool Batteries
DEWALT 12-Inch Miter Saw, 15-Amp, Single Bevel, Compound (DWS715),Black
This compound miter saw makes repeatable crosscuts and angled cuts for camper-van cabinetry and framing. A stable work area and proper stock support help produce consistent parts before installation.
View On Amazon: DEWALT 12-Inch Miter Saw, 15-Amp, Single Bevel, Compound (DWS715),Black
DEWALT Miter Saw Stand, 1,000 lb Capacity, Lightweight and Portable, Leg Locks for Easy Set Up, Mounting Brackets Included (DWX725B)
This portable work stand includes mounting brackets for a compatible miter saw. It provides a dedicated cutting station while building camper-van cabinetry and folds for workshop storage.
View On Amazon: DEWALT Miter Saw Stand, 1,000 lb Capacity, Lightweight and Portable, Leg Locks for Easy Set Up, Mounting Brackets Included (DWX725B)
COMOWARE Circular Miter Saw Blade - 12-inch 100 Tooth TCG Metal Saw Blade, 1 inch Arbor Heavy Duty for Aluminum and Non Ferrous Metals
This metal-cutting circular blade is intended for cutting suitable aluminum and other nonferrous stock during a camper-van build. Its tooth geometry differs from a general wood blade, so match it to the saw and work material.
View On Amazon: COMOWARE Circular Miter Saw Blade - 12-inch 100 Tooth TCG Metal Saw Blade, 1 inch Arbor Heavy Duty for Aluminum and Non Ferrous Metals
DEWALT Cordless Impact Driver Kit
This cordless impact-driver kit combines the fastening tool with battery and charging equipment. Its hex-bit holder accepts driver bits for installing and removing screws.
View On Amazon: DEWALT Cordless Impact Driver Kit
NEIKO 10048A Security Bit Set
This bit set brings several standard and security fastener profiles into one case. It supports removal and installation of the different screw heads encountered in build hardware.
View On Amazon: NEIKO 10048A Security Bit Set
DEWALT Folding Metric Hex Keys
This folding set keeps metric hex keys together in one handle. The individual keys rotate out for turning hex-socket fasteners.
View On Amazon: DEWALT Folding Metric Hex KeysNotes
- I placed a beam of the 2020 aluminum extrusion on top of the Flatline Roof Rack 80/20 extrusion to light the LED light bar up high enough so it could be angled down towards the ground.
- I used Thread Locker on all bolts to avoid unscrewing over time due to the vibration of the van on the road.
- The T Nuts for the 80/20 extrusion could not be dropped in, and instead had to be slid in at a wide opening on one side of the extrusion. Not realizing his, I had to undo the bolts I had previously tightened in order to slide in another T Nut. However, once the T Nut was slid in, it was easy to bolt into.
- The T Nuts for the 2020 extrusion can be dropped in, but they were more difficult to screw the bolt into because they would move and spin around in the channel. I had to use the thin bars of the allen wrench to fish the T Nuts around in the channel and position correctly, which was time consuming.
Pictures
Short Video
Long-Form Article
What The Mounting Notes Establish
The original steps document a 58-inch extrusion beam, three 1.75-inch connecting brackets and the hardware used to attach the beam and light bar. These are dimensions and parts recorded for this build. Measure your own assembly and identify the exact rack, extrusion profiles and mounting hardware before adapting it.
I raised the bar on the added extrusion so it could be angled toward the ground. The notes also record two different T-nut behaviors: the rack's 80/20 nuts needed to slide in from an opening, while the 2020 nuts could be inserted in the channel but were harder to align. Planning nut placement before tightening the assembly would have avoided undoing some bolts.
The material cards identify the bar as Nilight 71017C-A. The recorded thread-locker use and fastening sequence are build observations.
Match The Rack Variant And Hardware
The Flatline Rack Listing And Installation Guides separates model-year ranges and fairing styles, including a 50-inch light-bar cutout option. Identify your rack variant and consult its matching instructions before selecting parts. The 54-inch mount in this journal uses additional extrusion above the rack.
The notes list 1/4-20 hardware for the existing rack extrusion and M5 hardware for the added 2020 extrusion. The 80/20 And 2020 Extrusion Comparison explains why the brand, profile size and slot hardware need separate checks.
Follow The Wiring Work
Roof Wiring and Devices Project Day 1 records junction boxes, conduit and power-wire work for the roof lights. Continue through the Build Diary for later progress. For the exact items listed during this mounting job, return to Materials Used and Tools Used above.
The equipment guide covers the lights, stereo and cameras in my van.
