Illustration accompanying Day 94: Installing 54" LED Light Bar
A serene desert scene at dusk with a camper van featuring a newly installed LED light bar, highlighting the van's readiness for night-time adventures

Projects

  • Installing 54" LED Light Bar

Project Status

  • Completed

Time Spent

  • 5 Hours

Steps Taken

  1. 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
  2. Cut three (3) 1.75" aluminum mounts with miter saw for connecting 2020 extrusion to 80/20 extrusion
  3. Drill two holes in each aluminum mount 1" apart for mounting to extrusion
  4. Mount extrusion together with aluminum mounts
    1. 80/20 mount: 1/4-20 bolts, lock washer, flat washer
    2. 2020 mount: M5 bolts
  5. Mount LED light bar with 1/4-20 bolts and flat washer to 2020 extrusion
  6. Thread Locker was used on all bolts

Plans For Tomorrow

  1. 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.
Nilight - 71017C-A 54" 312W Curved LED Work Light

Nilight - 71017C-A 54" 312W Curved LED Work Light

EXTREMELY BRIGHT: 104 x 3W High Power LED Chips, super bright and powerful LED light bar dispels the darkness

View On Amazon
Ixgnij 10Pcs 2000Mm T Slot 2020 Aluminum Extrusion

Ixgnij 10Pcs 2000Mm T Slot 2020 Aluminum Extrusion

High-strength European standard aluminum profile, the surface is anodized, making the surface smoother and cleaner.

View On Amazon
180Pcs M5 T-Nuts Screws Assortment Kit

180Pcs M5 T-Nuts Screws Assortment Kit

For 2020 extrusion

View On Amazon
60Pcs 1/4-20 X 3/4" Button Head Socket Cap Bolts Screws

60Pcs 1/4-20 X 3/4" Button Head Socket Cap Bolts Screws

For 80/20 extrusion

View On Amazon
Small Parts 18-8 Stainless Steel Flat Washer (Pack Of 100)

Small Parts 18-8 Stainless Steel Flat Washer (Pack Of 100)

For 1/4-20 80/20 extrusion screws

View On Amazon
The Hillman Group 300018 1/4" Split Lock Washer, Steel, 100 Pieces

The Hillman Group 300018 1/4" Split Lock Washer, Steel, 100 Pieces

For 1/4-20 80/20 extrusion screws

View On Amazon
Medium Strength Thread Locker 243

Medium Strength Thread Locker 243

Threadlocker: Thread locker has strong adhesion and can fix screws, nuts, and metal fasteners to prevent loosening due to vibration.

View On Amazon
M5 Flat Washer, 18-8 (304) Stainless Steel Washers Flat, 100Pcs

M5 Flat Washer, 18-8 (304) Stainless Steel Washers Flat, 100Pcs

For 2020 extrusion screws

View On Amazon
12 Pieces Square Aluminum Flat Bar, 1/8" Thickness X 1.2" Width X 12" Length

12 Pieces Square Aluminum Flat Bar, 1/8" Thickness X 1.2" Width X 12" Length

Aluminum flat bar is made of aluminum 6061 which has a excellent corrosion resistance performance,lightweight and sturdy.

View On Amazon
Standard Slide-In T-Nut 1/4-20 Thread (25 Pack)

Standard Slide-In T-Nut 1/4-20 Thread (25 Pack)

For 80/20 extrusion

View On Amazon
Transit Van Low Pro Roof Rack | 148" High Rook Extended

Transit Van Low Pro Roof Rack | 148" High Rook Extended

The 148” High Roof Extended Low Pro Ford Transit Roof Rack is aerodynamic, completely adjustable, and easy to install. If you are looking for a premium quality roof rack at an affordable price - you’ve found it!

View Product

Tools Used

Dewalt DCD794B 20V MAX Atomic Compact Series Brushless Lithium-Ion 1/2 In. Cordless Drill Driver

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

View On Amazon
Dewalt Titanium Nitride Coated Drill Bit Set, Pilot Point, 21-Piece

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

DEWALT drill bit set has connectable accessory storage system to optimize storage space

View On Amazon
Dewalt 12-Inch Miter Saw, 15-Amp, Single Bevel, Compound (DWS715)

Dewalt 12-Inch Miter Saw, 15-Amp, Single Bevel, Compound (DWS715)

Stainless-steel miter detent plate of 12-inch miter saw blade comes with 14 positive stops

View On Amazon
Dewalt Miter Saw Stand, Heavy Duty With Miter Saw Mounting Brakets (DWX725B)

Dewalt Miter Saw Stand, Heavy Duty With Miter Saw Mounting Brakets (DWX725B)

Compact design of DEWALT miter saw stand allows easy transport and storage

View On Amazon
Comoware Circular Miter Saw Blade - 12-Inch 100 Tooth Tcg Metal Saw Blade

Comoware Circular Miter Saw Blade - 12-Inch 100 Tooth Tcg Metal Saw Blade

UNIQUE DESIGN: Silencer groove, reduce vibration and noise, Smooth Cutting, High Hardness Carbide Tip, provide a longer service life. TCG Design，Triple Chip Grind includes a 15-degree hook angle.

View On Amazon
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

View On Amazon
Neiko 10048A Security Bit Set 100-Piece 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!

View On Amazon
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°

View On Amazon

Notes

  • 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

in the middle of nowhere in the phoenix, arizona desert
in the middle of nowhere in the phoenix, arizona desert
dewalt miter saw and miter saw stand
dewalt miter saw and miter saw stand
dewalt miter saw and miter saw stand
dewalt miter saw and miter saw stand
80/20 and 2020 extrusion and DIY aluminum mount with bolts and washers
80/20 and 2020 extrusion and DIY aluminum mount with bolts and washers
80/20 and 2020 extrusion and DIY aluminum mount with bolts and washers
80/20 and 2020 extrusion and DIY aluminum mount with bolts and washers
Nilight - 71017C-A 54" 312W Curved LED light bar before mounting
Nilight - 71017C-A 54" 312W Curved LED light bar before mounting
Nilight - 71017C-A 54" 312W Curved LED light bar after mounting rear view
Nilight - 71017C-A 54" 312W Curved LED light bar after mounting rear view
bolt and washer for mounting Nilight - 71017C-A 54" 312W Curved LED light bar
bolt and washer for mounting Nilight - 71017C-A 54" 312W Curved LED light bar
Nilight - 71017C-A 54" 312W Curved LED light bar after mounting front view
Nilight - 71017C-A 54" 312W Curved LED light bar after mounting front view
Nilight - 71017C-A 54" 312W Curved LED light bar after mounting front view
Nilight - 71017C-A 54" 312W Curved LED light bar after mounting front view

Short Video

https://youtu.be/CNcb9cEGhNQ

Long-Form Article

Installing A 54" LED Light Bar On A Camper Van

A detailed close-up of a hand using a cordless drill to attach an LED light bar on a camper van roof, showcasing the precision of the DIY installation process against a bright desert backdrop

Enhancing The High Roof Extended Van With A 54" LED Light Bar: A Project Freedom Adventure

Overview

In my latest endeavor at Project Freedom, I took on the exciting challenge of enhancing my 2023 Ford Transit 250 High Roof Extended van by installing a 54" LED light bar. This high-quality addition is set to brighten my journey, providing unparalleled safety and visibility as I navigate through the deserts of Phoenix, AZ. This project, a testament to the spirit of adventure and meticulous planning documented on Project Freedom (campervanfreedom.com), highlights the fusion of hands-on effort with high-strength materials and power tools.

Project Status

  • Completion: Achieved
  • Time Investment: 5 Hours

Execution Steps

  1. Preparation with Precision:
    • Initiated by making angled cuts on a 2020 aluminum extrusion to 58 inches using a sliding compound miter saw. This piece was designed to rest atop an existing piece of the Flatline roof rack, showcasing a blend of high strength and functionality.
    • Created three 1.75" aluminum mounts with the miter saw, establishing connections between the 2020 extrusion and the robust 80/20 framework.
  2. Assembly with Accuracy:
    • Ensured secure attachment by drilling evenly spaced holes in each mount for the LED work light and other components.
    • Assembled the framework using 1/4-20 bolts with stainless steel lock and flat washers for the 80/20 mount, and M5 bolts for the 2020 mount, showcasing our commitment to durable and high-quality construction.
  3. Illuminating Installation:
    • Mounted the LED light bar, a beacon of brightness, using 1/4-20 bolts and flat washers on the 2020 extrusion, ensuring a firm bond with medium strength thread locker to withstand the vibrations of the road.
An array of DIY tools spread out on a wooden table in the desert, capturing the essence of a camper van conversion project at sunset, symbolizing adventure and the spirit of self-reliance

Materials And Tools

  • Materials Used: Featured a wide variety of aluminum extrusion, bolts, washers, and thread locker, highlighted by the Nilight - 71017C-A 54" 312W Curved LED Work Light, a testament to our dedication to high-quality and affordable products.
  • Tools Employed: Leveraged high-quality power tools and hand tools, including the Dewalt DCD794B 20V MAX ATOMIC COMPACT SERIES Drill Driver and DEWALT 12-Inch Miter Saw, ensuring precision and reliability on job sites.

Insights And Observations

The project underscored the importance of precision and the high bonding strength of thread locker, critical for the project's long-term durability. It also brought to light the iterative nature of hands-on projects, especially when dealing with a wide range of high-quality materials and tools.

Next Steps

With the LED work lights now casting a wide and bright path ahead, the next adventure involves the installation of solar panels and a roof vent fan, further equipping the van for off-grid living. This progression stands as a testament to Project Freedom's commitment to exploring new horizons with affordable, high-quality solutions and exceptional customer service.

Stay tuned to Project Freedom for more updates on this journey, as we continue to transform a high roof extended van into a beacon of adventure and freedom on the open road.