Illustration accompanying Day 103: Electrical Wiring and Devices on Roof - Day 7
Van with open roof showing detailed wiring in a desert setting

Projects

  • PVC electrical wire conduit system on roof with junction boxes

Project Status

  • In progress

Time Spent

  • 8 Hours

Steps Taken

  1. Run wires through large junction box into van
  2. Run small LED light wires through wire gland in large junction box
  3. Run camera ethernet cat 6 cable through gland into PVC tee adapter
  4. Drill holes in small plastic junction box
  5. Install male threaded PVC adapter and plastic nut in small junction box
  6. Connect three (3) small LED light wires together with wire nut at large junction box and wrap with electrical tape
  7. Drill holes in large junction box
  8. Install male threaded PVC adapter and plastic nut in large junction box
  9. Connect PVC tubing to large junction box
  10. Run all wires from driver side of van to passenger side through large junction box and down into van
  11. Cement all PVC connections together

Plans For Tomorrow

  • Continue work on PVC conduit system and running wires

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, Human/Vehicle Detection, 100Ft IR Night Vision, Work with Smart Home, Up to 256GB microSD Card, RLC-510A (Black)

REOLINK IP Security Camera Outdoor, 5 MP Home Surveillance Outdoor Indoor PoE Camera, Human/Vehicle Detection, 100Ft IR Night Vision, Work with Smart Home, Up to 256GB microSD Card, RLC-510A (Black)

This wired security camera uses onboard detection to distinguish people, vehicles and other supported events. It can help monitor a parked camper van when suitable power, networking and a secure mounting position are available.

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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 Spotlights, 10Pack

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 Spotlights, 10Pack

These SanYoung LED pods provide auxiliary illumination around a van. Their mounting brackets attach the lamp housings to a supporting surface.

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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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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 Cable Tie Tool for Metal Cable Zip Ties Tensioning Cutter Metal Zip Tie Tool Kit Self-Locking Zip Ties Kit

This cable-tie tool kit is listed for tensioning and trimming stainless-steel ties. It may support van assembly tasks where metal ties are appropriate.

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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), Multi-Purpose Heavy-Duty Stainless Steel Zip Tie With Uv Resistance, Suitable For Outdoor Fixing Of Pipes, Machinery, Wire Mesh, Fences, Etc.

The reviewed stainless-steel ties include screw-mount bases for attaching bundled items to a surface. They may organize suitable van components where the mounting surface, cable protection and fastening method are appropriate.

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Oatey Clear PVC Cement

Oatey Clear PVC Cement

This clear PVC cement bonds PVC pipe and fittings at their mating surfaces. It is supplied in a small can for making solvent-welded PVC joints.

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

This clear silicone sealant creates flexible seals around compatible kitchen and bathroom joints. In a camper van it can help finish sink or shower edges where the fixture and sealant instructions allow its use.

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Otdorpatio 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)

Otdorpatio 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)

This project enclosure is listed for housing suitable electrical components. It may protect a van wiring project when mounting, heat and cable entries are properly designed.

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Otdorpatio 2 Packs Junction Box IP65 Waterproof ABS Plastic Electrical Project Case Power Junction Boxes, Project Box with 8 PCS M16 Cable Glands 3.94x2.68x1.97 inch(100x 68 x50 mm)

Otdorpatio 2 Packs Junction Box IP65 Waterproof ABS Plastic Electrical Project Case Power Junction Boxes, Project Box with 8 PCS M16 Cable Glands 3.94x2.68x1.97 inch(100x 68 x50 mm)

These junction boxes house suitable cable connections or small electronics in a camper-van installation. Cable glands can help organize entries and reduce moisture intrusion when correctly sized and tightened.

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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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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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DOWELL Wire Stripper

DOWELL Wire Stripper

This hand tool strips insulation from electrical wire and includes a wire-cutting edge. Its shaped handles provide a grip for repeated wiring tasks.

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VEVOR 1/2" Drive Impact Socket Set, 65 Piece SAE 3/8" to 1-1/4" and Metric 10-24mm, 6 Point Cr-V Alloy Steel for Auto Repair, Easy-to-Read Size Markings, Rugged Construction, Storage Case

VEVOR 1/2" Drive Impact Socket Set, 65 Piece SAE 3/8" to 1-1/4" and Metric 10-24mm, 6 Point Cr-V Alloy Steel for Auto Repair, Easy-to-Read Size Markings, Rugged Construction, Storage Case

This impact-socket assortment helps loosen and tighten a range of vehicle and conversion fasteners. The storage case keeps metric and SAE sizes organized for workshop use or a van maintenance kit.

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Pictures

pvc conduit system on roof of camper van with wires running through top of van to electrical system inside
pvc conduit system on roof of camper van with wires running through top of van to electrical system inside
plastic junction box with drilled hole for insertion of male threaded pvc for pvc conduit system on roof of camper van conversion
plastic junction box with drilled hole for insertion of male threaded pvc for pvc conduit system on roof of camper van conversion
plastic junction box with male threaded pvc for pvc conduit system on roof of camper van conversion
plastic junction box with male threaded pvc for pvc conduit system on roof of camper van conversion
plastic junction box with male threaded pvc for pvc conduit system on roof of camper van conversion
plastic junction box with male threaded pvc for pvc conduit system on roof of camper van conversion
plastic junction box with electrical wires, wire glands, wire nut, and electrical tape for pvc conduit system on roof of camper van conversion
plastic junction box with electrical wires, wire glands, wire nut, and electrical tape for pvc conduit system on roof of camper van conversion
pvc conduit system on roof of camper van conversion
pvc conduit system on roof of camper van conversion
pvc conduit system on roof of camper van conversion
pvc conduit system on roof of camper van conversion
top view of plastic junction box and wires pvc conduit system on roof of camper van conversion
top view of plastic junction box and wires pvc conduit system on roof of camper van conversion
top view of plastic junction box and wires pvc conduit system on roof of camper van conversion
top view of plastic junction box and wires pvc conduit system on roof of camper van conversion
top view of plastic junction box and wires pvc conduit system on roof of camper van conversion
top view of plastic junction box and wires pvc conduit system on roof of camper van conversion
side view of plastic junction box, wire glands, pvc attachment, and wires pvc conduit system on roof of camper van conversion
side view of plastic junction box, wire glands, pvc attachment, and wires pvc conduit system on roof of camper van conversion
reolink security camera and 8020 aluminum extrusion mount and small led light on stop of camper van conversion
reolink security camera and 8020 aluminum extrusion mount and small led light on stop of camper van conversion
reolink security camera and ethernet cat 6 cable gland going into tee adapter of pvc conduit system on roof of camper van conversion
reolink security camera and ethernet cat 6 cable gland going into tee adapter of pvc conduit system on roof of camper van conversion
pvc conduit system on roof of camper van conversion
pvc conduit system on roof of camper van conversion

Short Video

Long Form Article

Close-up of hands installing a security camera on the van roof in a desert

PVC Electrical Wire Conduit System Installation

Project Status: In Progress

Time Spent: 8 Hours

Today, I continued the intricate process of installing an electrical wiring system on the roof of my van, utilizing a comprehensive PVC pipe framework to house and protect the wiring. Here’s a detailed account of the steps taken and materials used:

Steps Undertaken:

Large Junction Boxes Setup:

  • Routed various electrical cables from a large junction box into the van, including the neutral and hot wires.
  • Passed small LED light wires and a camera ethernet CAT 6 cable through a gland into a PVC tee adapter, ensuring that each connection met the National Electric Code for safety and efficiency.

Small Plastic Junction Box Configuration:

  • Drilled entry points in a small plastic junction box for cable management.
  • Installed a PVC male adapter and secured it with a plastic nut, emphasizing a corrosion-resistant connection suitable for industrial applications.

Wiring and Sealing:

  • Linked three LED light wires using TICONN solder seal wire connectors, known for their high quality and insulated properties, then wrapped the connection in electrical tape to ensure durability and safety.
  • Attached copper clad aluminum wire segments, chosen for their electrical conductivity and lightweight nature, across the van from the driver side to the passenger side through the electrical junction boxes.

Finalizing PVC Connections:

  • Secured and cemented all PVC connections together, using a mix of white wire for neutral and color-coded wires for easy identification.
Night scene with van in desert, LED lights brightening the surrounding area

Materials Used:

Tools Deployed:

Plans For Tomorrow:

I plan to continue enhancing the PVC conduit system and finalize the wiring setup, ensuring every wire and cable is securely managed and meets all regulatory standards.

This meticulous approach not only ensures a robust electrical box setup but also enhances the overall functionality and safety of my mobile home, turning it into a well-equipped camper van ready for adventures.