Projects
- PVC electrical wire conduit system on roof with junction boxes
Project Status
- Finished
Time Spent
- 12 Hours
Steps Taken
- Run wires through roof of van
- Install plastic trim around hole into van to protect wires
- Run wires through PVC conduit system using fish tape wire puller
- Pull wires through PVC conduit system
- Add wire gland for passenger security camera to ensure it is waterproof
- Connect PVC pipes together
- Cover wires with heat gun and tubing where wire was exposed due to stripping
- Solder seal last LED light hot red wire and neutral black wire together
- Cover all junction boxes
- Cement all remaining PVC parts together
- Add metal zip ties and tighten around entire PVC conduit system
Plans For Tomorrow
- Start work on roof storage system
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)
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.
View On Amazon: 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)
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.
View On Amazon: 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
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.
View On Amazon: 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
Sigma 14240 Blank Outlet-Box Cover
This blank cover closes the face of a single-gang electrical box. It provides a removable cover where no switch or receptacle is fitted.
View On Amazon: Sigma 14240 Blank Outlet-Box Cover
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
These cable glands seal and grip compatible cables at enclosure entries. They can provide strain relief where van wiring enters project boxes.
View On Amazon: 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
TICONN 150 PCS Solder Seal Wire Connectors, Heat Shrink Butt Connectors, Waterproof and Insulated Electrical Wire Terminals, Butt Splice (150PCS)
These TICONN connectors join appropriately sized wires using a solder ring and heat-shrink sleeve. They can serve selected van wiring repairs with controlled heating and proper strain relief.
View On Amazon: TICONN 150 PCS Solder Seal Wire Connectors, Heat Shrink Butt Connectors, Waterproof and Insulated Electrical Wire Terminals, Butt Splice (150PCS)
GS Power Primary Automotive Wire
This automotive primary wire provides insulated conductors for wiring runs. Its copper-clad aluminum construction is recorded in the product listing.
View On Amazon: GS Power Primary Automotive Wire
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.
View On Amazon: Jadaol Flat Ethernet Cable
Three-Quarter-Inch PVC Pipe Sections
These short PVC pipe sections provide rigid tubing for a fabrication project. They join with matching fittings to form a pipe assembly or frame.
View On Amazon: Three-Quarter-Inch PVC Pipe Sections
Three-Quarter-Inch PVC Male Adapters
These PVC adapters connect a socket joint to a male pipe-threaded end. They provide a transition between the two connection styles in a PVC assembly.
View On Amazon: Three-Quarter-Inch PVC Male Adapters
Three-Quarter-Inch PVC Elbows
These angled PVC fittings join two pipe sections through a change in direction. Their socket ends form part of a pipe frame or other PVC assembly.
View On Amazon: Three-Quarter-Inch PVC Elbows
PVC Socket-To-Female-Thread Adapters
These PVC fittings connect a slip socket to a female pipe-threaded connection. They change the connection style within a PVC assembly.
View On Amazon: PVC Socket-To-Female-Thread Adapters
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.
View On Amazon: 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
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.
View On Amazon: 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.
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.
View On Amazon: Oatey Clear PVC Cement
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.
View On Amazon: GE Advanced Silicone Caulk for Kitchen & Bathroom - 100% Waterproof Silicone Sealant, 5X Stronger Adhesion, Shrink & Crack Proof - 10 oz Cartridge, Clear, Pack of 1
Amazon Basics Electrical Tape
This black electrical tape wraps around wire joints and cable bundles. Its flexible adhesive backing conforms to small bends during wiring work.
View On Amazon: Amazon Basics Electrical Tape
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.
View On Amazon: 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 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.
View On Amazon: 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)
Heat Shrink Tubing Kit - 3:1 Ratio Adhesive Lined, Marine Grade Shrink Wrap - Automotive Industrial Heat-Shrink Tubing - Black, Red - 400 PCS
This adhesive-lined heat-shrink tubing seals around a connection as it contracts under heat. It can finish compatible camper-van wiring repairs when the tubing size and temperature rating suit the cable and joint.
View On Amazon: Heat Shrink Tubing Kit - 3:1 Ratio Adhesive Lined, Marine Grade Shrink Wrap - Automotive Industrial Heat-Shrink Tubing - Black, Red - 400 PCS
SYOAUTO 65Ft(20M) Door Edge Guard Black Car Door Edge Guards Door Edge Protector for Cars Rubber Auto Door Trim U Shape Build in Metal Sheet No Need Adhesive Easy to Cut Door Guards for Most Cars
This edge trim covers exposed vehicle door edges. Its flexible profile follows the edge during installation.
View On Amazon: SYOAUTO 65Ft(20M) Door Edge Guard Black Car Door Edge Guards Door Edge Protector for Cars Rubber Auto Door Trim U Shape Build in Metal Sheet No Need Adhesive Easy to Cut Door Guards for Most Cars
Tintvent Automotive Door Edge Trim Molding Kit with Tape, L Shaped Lip Guard for Car Fenders, Running Boards, Camper Shells, Spas, Mirrors Edge and More, Black(26Feet)
This adhesive-backed L-shaped trim covers an exposed edge with a flexible lip. Its black profile provides a finished border around an interior trim piece.
View On Amazon: Tintvent Automotive Door Edge Trim Molding Kit with Tape, L Shaped Lip Guard for Car Fenders, Running Boards, Camper Shells, Spas, Mirrors Edge and More, Black(26Feet)Tools 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 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 Keys
Milwaukee 49-22-4185 Hole Saw Kit
This hole-saw kit provides several cutting diameters in a carrying case. It makes circular openings for fittings, cable routes and other fabrication work.
View On Amazon: Milwaukee 49-22-4185 Hole Saw Kit
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.
View On Amazon: DOWELL Wire Stripper
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.
View On Amazon: 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
HORUSDY Drill Socket Adapters
These adapters connect sockets to a drill or driver through a hex shank. The different square-drive ends accommodate several socket sizes.
View On Amazon: HORUSDY Drill Socket Adapters
DEWALT 20V MAX Heat Gun, Cordless, Up to 990 Degrees, 42 Minutes of Run Time, LED Light, Bare Tool Only (DCE530B)
This cordless heat gun provides directed hot air with an LED work light and lock-on control. It can help with suitable heat-shrink tubing and other heat-assisted camper-van build tasks without needing an outlet at the work location.
View On Amazon: DEWALT 20V MAX Heat Gun, Cordless, Up to 990 Degrees, 42 Minutes of Run Time, LED Light, Bare Tool Only (DCE530B)
DEWALT 20V MAX Battery, 6 Ah, 2-Pack, Fully Charged in Under 90 Minutes (DCB206-2)
These DEWALT batteries power compatible 20V MAX cordless tools. They can supply van-build tools when charged and stored according to manufacturer instructions.
View On Amazon: DEWALT 20V MAX Battery, 6 Ah, 2-Pack, Fully Charged in Under 90 Minutes (DCB206-2)Pictures
Short Video
Long Form Article
I dedicated a full 12 hours on the eighth day to successfully complete the installation of a PVC electrical wire conduit system along with junction boxes on the roof of my van. This installation is a crucial part of my van conversion project, ensuring safe and efficient electrical routing. ?️
For the wider build, see my camper van electrical system and the equipment I used.
Steps Taken:
- Initiating Installation: Started by running wires through the roof of the van. ?️
- Protecting the Wires: Installed plastic trim around the entry hole into the van to safeguard the wires. ?️
- Routing Wires: Employed a fish tape wire puller for threading wires through the PVC conduit system. ?
- Securing the System: Added a waterproof wire gland for the passenger security camera. ??
- Assembling PVC Pipes: Connected all PVC pipes and sealed them. ?
- Insulating Exposed Wires: Used a heat gun and tubing to cover exposed wires after stripping. ?
- Soldering Connections: Solder sealed the last LED light's hot red wire and neutral black wire. ?
- Finalizing the Setup: Covered all junction boxes and cemented any remaining PVC parts together. ?
- Reinforcing with Ties: Added metal zip ties and tightened around the entire PVC conduit system for extra security. ?️
Materials Used:
Tools Used:
? Plans For Tomorrow:
I will begin work on the roof storage system, aiming to maximize the utility and space efficiency of my van. ?