Illustration accompanying Day 95: Electrical Wiring and Devices on Roof - Day 1
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.

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.
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

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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.

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180Pcs M5 T-Nuts Screws Assortment Kit

180Pcs M5 T-Nuts Screws Assortment Kit

For 2020 extrusion

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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

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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

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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

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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.

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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

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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.

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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

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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!

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Sealproof 1-Gang 3 1/2-Inch Holes Weatherproof Rectangular Exterior Electrical Outlet Box

Sealproof 1-Gang 3 1/2-Inch Holes Weatherproof Rectangular Exterior Electrical Outlet Box

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Sigma Engineered Solutions, Gray 14240 1-Gang Rectangular Stamped Weatherproof Cover

Sigma Engineered Solutions, Gray 14240 1-Gang Rectangular Stamped Weatherproof Cover

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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

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

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Ticonn 150 Pcs Solder Seal Wire Connectors, Heat Shrink Butt Connectors, Waterproof And Insulated Electrical Wire Terminals, Butt Splice (150Pcs)

Ticonn 150 Pcs Solder Seal Wire Connectors, Heat Shrink Butt Connectors, Waterproof And Insulated Electrical Wire Terminals, Butt Splice (150Pcs)

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Gs Power 12 Gauge Stranded Flexible Copper Clad Aluminum Cca Primary Automotive Wire

Gs Power 12 Gauge Stranded Flexible Copper Clad Aluminum Cca Primary Automotive Wire

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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

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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

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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

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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

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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.

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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

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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!

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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°

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Dewalt 20V MAX Heat Gun, Cordless, Up To 990 Degrees, 42 Minutes Of Run Time, LED Light, Bare Tool Only (DCE530B)

Dewalt 20V MAX Heat Gun, Cordless, Up To 990 Degrees, 42 Minutes Of Run Time, LED Light, Bare Tool Only (DCE530B)

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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
Day 95: Electrical Wiring and Devices on Roof - Day 1 — reference image
2020 aluminum extrusion on camper van roof
Day 95: Electrical Wiring and Devices on Roof - 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

https://youtu.be/-ti3V763ZkM?si=PqqyKOos4X_RpMoY

Long-Form Article

Projects: A Van Life Adventure

In my latest Project Freedom endeavor, I set out on a multifaceted modification project for my Ford Transit, aiming to boost functionality and comfort for my life on the road. This video diary is a personal account of my journey through the installation of PVC conduit, junction boxes, LED lighting, and a solar panel setup, all significant strides in my pursuit of freedom and efficiency within the van life community.

Project Status: Not Complete

Time Spent: 12 Hours

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.

Embarking On Enhanced Living

My project kicked off with a clear vision: to upgrade my van’s electrical and lighting systems for seamless integration with my existing Flatline Rack 80/20 extrusion. This goal was ambitious, reflecting my commitment to the comfort and practicality essential for living the van life at a high level.

Step-By-Step Towards The Bigger Picture

Project management was all on me, unfolding in detailed steps that painted the bigger picture of Project Freedom:

  • The assembly of a metal junction box and meticulous drilling for wire glands were my first steps towards a secure electrical foundation.
  • Soldering and splicing power wires, coupled with running power and Ethernet wires through the junction box, guaranteed a seamless electrical flow.
  • I then moved the Flatline Roof Rack and added 2020 aluminum extrusion to boost the structural integrity and versatility of my setup.
  • A key highlight was installing tiny LED lights, ensuring my nights were bathed in efficient, soft illumination.
  • The careful process of positioning solar panels on the roof was a testament to my commitment to sustainable living on the open roads.

Materials And Tools: The Foundation Of My Project

I chose a range of materials and tools for their quality and compatibility with my van life requirements, from the Nilight LED Work Light to the Sealproof Weatherproof Electrical Outlet Box. Employing tools from DEWALT's Cordless Drill Driver to the Heat Gun was crucial in bringing my vision to life.

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.

Challenges And Triumphs On The Road

The journey wasn’t smooth sailing. From minor injuries to battles against time and the elements, each obstacle was met with relentless determination. Yet, witnessing a beautiful sunset around my workspace was a profound reminder of why I chose this life adventure.

Reflections And Forward Steps

Reflecting on the progress, I'm reminded of van life's essence—a mix of challenges, innovation, and the relentless pursuit of freedom. While my project isn't complete, every step is a testament to the personal growth journey inherent in the van life community. My project embodies the life adventure that van living offers, from practical enhancements to aesthetic uplifts.

Staying Connected

For those interested in my journey, eager to learn more about my projects, or looking to share insights, I'm active on social media and within various Facebook groups, connecting with like-minded van lifers. You can also reach me via email at steve@campervanfreedom.com. Whether you're a seasoned van lifer or just starting your path to freedom, I welcome you to join me in this ever-evolving adventure, where working spaces often blend with mountain biking trails, and the box office is the stunning view from our windows.