Roof work in progress with LED pods, loose cables and tools on the van rack

Roof Wiring and Devices Project Day 1 records 12 hours starting the roof wiring and LED-light work on the Ford Transit. I assembled junction boxes, added wire glands and PVC conduit, routed power and Ethernet cables, and made mounts for two small lights on the passenger side of the roof rack.

This was work in progress. The notes say the project was not complete; the solar panels were brought onto the roof for fitting. For the earlier light-bar mount, read Light Bar Mounting. The roof work continues in Roof Wiring and Devices Project Day 2.

See The Materials Used See The Tools Used

Projects

  • Installing PVC conduit and junction boxes on roof
  • Running power and ethernet wires through conduit
  • Installing 2020 aluminum extrusion on existing Flatline Rack 80/20 extrusion
  • Installing small LED lights

Project Status

  • Not complete

Time Spent

  • 12 Hours

Steps Taken

  1. Put mental junction box together
  2. Drill holes in junction box for wire glands
  3. Install wire glands in drilled holes in junction box
  4. Use heat gun and solder seal wire connectors to splice power wires from LED light bar together
  5. Run power and ethernet wires through junction box
  6. Cut PVC pipe and install on junction box
  7. Move Flatline Roof Rack 80/20 extrusion cross beams to fit length of solar panels
  8. Install 2020 aluminum extrusion on top of Flatline Roof Rack 80/20 extrusion with corner brackets
  9. Bring 2 solar panels up on roof for fitting purposes
  10. Cut 2020 extrusion to size
  11. Cut and drill holes in flat aluminum plates to size to lift up small LED lights (2 plates per light)
  12. Mount 2 small LED lights on 2020 extrusion on passenger side of roof

Plans For Tomorrow

  1. Continue work on roof electrical items

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

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.

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IXGNIJ 10pcs 2000mm T Slot 2020 Aluminum Extrusion European Standard Anodized Linear Rail for 3D Printer Parts and CNC DIY Black(78.7'')

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.

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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

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.

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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 with 3 Outlet Holes, Three 1/2" Holes, Single Gang, UL Listed

This single-gang weatherproof electrical box encloses suitable exterior connections. It can support a correctly designed camper-van outlet installation with a compatible cover and conduit fittings.

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Jadaol Flat Ethernet Cable

Jadaol Flat Ethernet Cable

This flat Ethernet patch cable connects network devices through modular plugs. Its low-profile cable shape helps route a wired connection along edges and confined spaces.

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Tools Used

DEWALT DCD794B Compact Drill/Driver

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.

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COMOWARE Circular Miter Saw Blade - 12-inch 100 Tooth TCG Metal Saw Blade, 1 inch Arbor Heavy Duty for Aluminum and Non Ferrous Metals

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.

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DEWALT Cordless Impact Driver Kit

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.

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NEIKO 10048A Security Bit Set

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.

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Notes

  • Sliced my fingers open several times. Big cut when running finger along metal mounts on solar panels. Bled all over everything and didn't care.
  • Beautiful sunset and clouds around 6 to 7pm.

Pictures

phoenix, arizona sunset in the desert with cactus and clouds
phoenix, arizona sunset in the desert with cactus and clouds
camper van roof electrical wires and conduit
camper van roof electrical wires and conduit
camper van roof electrical wires and conduit
camper van roof electrical wires and conduit
2020 aluminum extrusion on camper van roof
2020 aluminum extrusion on camper van roof
2020 aluminum extrusion on camper van roof
2020 aluminum extrusion on camper van roof
Roof Wiring and Devices Project Day 1 — reference image
2020 aluminum extrusion on camper van roof
Roof Wiring and Devices Project Day 1 — reference image
2020 aluminum extrusion on camper van roof
led light on top of camper van
led light on top of camper van
camper van roof electrical wiring and roof rack
camper van roof electrical wiring and roof rack
camper van roof electrical wiring and junction box and wire glands
camper van roof electrical wiring and junction box and wire glands
camper van roof electrical wiring and junction box and wire glands
camper van roof electrical wiring and junction box and wire glands

Short Video

Long-Form Article

What Was Done during the Roof Wiring and Devices Project Day 1 session

The original steps cover the first junction-box assembly, drilling for wire glands, splicing the light-bar power wires and routing power and Ethernet cables through the box. PVC pipe was cut and attached, the rack cross beams were moved to suit the solar-panel length, and additional 2020 extrusion was attached above the existing rack extrusion.

Two solar panels were brought onto the roof for fitting. The notes also describe cutting and drilling aluminum plates to lift the small LED lights and mounting two of those lights on the passenger side. This is a record of routing, fitting and mounting work.

Read The Materials As A Build Record

The Materials Used cards preserve the exact products listed for this day, including the junction box, cable glands, splice connectors, PVC pipe and LED lights. The Tools Used cards identify the drill, cutting tools, hex keys and heat gun used during the work. Open a product card to check the current item and its specifications against the job you are planning.

The recovered parts list names a 12-gauge copper-clad aluminum (CCA) wire.

The DC Wire Sizing And Protection Guide explains cable and protection selection. Victron’s DC Wiring Reference provides cable-selection and connection context.

Follow The Actual Sequence

Light Bar Mounting covers the custom light-bar mount. Roof Wiring and Devices Project Day 2 continues the roof work after this unfinished stage. Use the Build Diary to follow later conduit and wiring progress.

The original 12-hour entry, personal notes, photographs and short video remain above. They preserve what was recorded that day without turning the later recap into a claim of completed or tested performance.

A breathtaking sunset casts a warm glow over the Project Freedom van, highlighting the newly installed solar panels and LED lights, symbolizing progress in the van modification project.
A close-up view of a metal junction box mounted on the van's roof, showcasing detailed craftsmanship with drilled holes for wire glands and neatly arranged wires, reflecting the meticulous steps taken in the van's electrical enhancement.
Two small LED lights mounted on the 2020 extrusion on the passenger side of the van's roof, with the early evening light enhancing the van's functionality and aesthetics, offering a glimpse into the serene life on the road.