Solar Panels Installation

2x Grape Solar 160W

The autonomy of our DIY camper van conversion depends on power, and extracting power from the sun feels a bit like cheating to us. If you say freedom, we say solar panels! The key to freedom is to select appliance that draw low electrical consumption and then select the solar panel(s) and charge controller accordingly. More of that in our Electrical System Design page.

 

 

TIME SPENT ON THE JOB: 6 hours

 

TOTAL COST : 570$ USD

 

DISCLOSURE: This post contains affiliate links, which means that if you click and commit to buy one of the product linked, we will receive a commission fee. The price you pay remains the same, affiliate link or not. Buying through our affiliate links is a great way to say thanks if we were of any help in your van conversion! Alternatively, you can visit our Say Thanks! page.

 

MATERIAL:

  • 2 x Grape Solar 160W 12 volts panels ()
    • Grape Solar now sell 180W panels (same physical dimensions) (Buy from Amazon)
  • 3M VHB double-sided tape 1″ width  (Buy from Amazon)
  • 2 x Renogy Z mounting brackets (Buy from Amazon)
  • MC-4 Multibranch Connector pair (Buy from Amazon)
  • Right angle cable gland 3/8″ (Buy from Amazon)
  • 30′ Extension Cable with MC-4 Connectors 8AWG (Buy from Amazon) (cut in half to get 2 times 15 feet length)
  • Dicor 551 LSG-1 Lap Sealant (Buy from Amazon)
  • Isopropyl alcohol
  • Primer, Paint & Clearcoat

Solar Panels installation, material

 

TOOLS:

  • Drill
  • Caulking gun
  • File and sandpaper

 

HOW WE DID IT*

*Disclaimer: we’re good, but not that much. Use these instructions at your own risks!

 

1- Test the setup before the installation

Right when we finished installing everything, we realized that we did not test any of the components! If any item was defective (panel, connector, wire), we would have to disassemble everything… Fortunately, things always work for the best so we did not have to undo our work!

To test, we could have just connect the panels to the MC4 parallel connector, then connect to the extension cable, and finally check the voltage at the end of the extension cables. We did that at the very end of our installation.

 

2- Pre-install brackets on the solar panels (4 brackets for each panel)

It’s easier to do this on the ground…

Solar Panel Installation, fastener stackup

 

3- Relocate the brackets in the inside edge

This is to minimize the gap between the panels, so they are installed toward the middle of the roof and are less visible from the ground. A minimum gap should be left to account for thermal expansion and for installation access.

Solar Panel Installation, relocating bracket

 

4- Install 3M VHB tape on brackets

We selected 3M VHB tape to minimize drilling through the roof. AM Solar have been doing it for a long time and reported to never have lost a panel. Where a screw will grip through the sheet metal, the tape rely solely on the paint to hold; therefore, we don’t recommend to use tape on rusted, damaged or used paint. In other words, we trust the tape method because the van is NEW. Also, we check our panels installation regularly.

 

Per manufacturer recommendation, the minimum application temperature for 4991 tape is 60F.

Solar Panel Installation, apply 3M VHB to brackets

 

5- Cut the 30′ extension cable in half and pass it through the glands. Leave about 12 inches between connectors and gland.

It required a lot of force to pass the cable through the gland thanks to the right angle. It’s better to do this on the ground.

 

6- Pre-fit solar panels on the roof to define location of cable glands

This extension cable is not very flexible. We found it easier to work with if we install the glands at approximately 12 inches from the panels.

Mark the location of the solar panel to avoid having the measure again afterward.

 

7- Remove solar panels and drill holes for the glands

We pre-drilled and then use a hole saw.

Solar Panel Installation, drill roof

Solar Panel Installation, saw roof

 

8- Break the sharp edges with a file and smooth the surfaces with a fine sandpaper

To prepare the surface for touch-up.

Solar Panel Installation, file and sand

 

 

9- Apply Primer, Paint & Clearcoat on drilled holes

This is an important step to prevent corrosion in the future.

TIP: You can have your exact van color prepared for you in almost any auto-parts store. Just give them your color-code (printed on the driver’s door frame), year of production and make.

Solar Panel Installation, edge touch up

 

10- Think and prepare cable routing on solar panels

This is to prevent cable chafing on the roof and damaging the paint. We also installed a protective tape on the roof afterward just in case.

Now that we look at the picture below, we’re not sure it will pass the test of time. You might come up with a better idea!

Solar Panel Installation, cable routing

 

11- Fit solar panels on the roof and connect all the cables

See previous picture.

 

12- Pass wire through the roof without securing the glands yet

Solar Panel Installation, cable interior routing

 

 

13- Clean roof with isopropyl alcohol, peel off 3M VHB tape and press firmly to adhere

No picture here. We had to act fast and it turned out more complicated than anticipated: you get no access to the center of the roof, the cables must be neatly fitted and you get one chance only to stick the 3M tape at the right place…

 

14- Fasten the glands to the roof

 

15- Seal all the brackets and the glands with Dicor Lap Sealant

The bracket are sealed to prevent water contamination with the tape; it should help in the long run. We could not seal the inner edge of each bracket because we had no access.

Solar Panels Installation, sealing the brackets

 

 

16- Final Test

We don’t have the charge controller installed yet, but we can ensure there is voltage coming from the panels.

It works!

Solar Panel InstallationSolar Panel Installation, testing the voltage, testing the voltage

 

17- Have a pint of fresh Double I.P.A

We deserved it!

Solar Panel Installation, double IPA

 

18- Have a Poutine

We know what you are thinking; but we also know that you would love it if you try. This is Quebec fine cuisine. 

Solar Panel Installation, Poutine

 

ON SECOND THOUGHT…

We chose a PWM charge controller because it is cheaper; we were then “forced” to use 12V solar panel (because the excess voltage with PWM is lost, while a MPPT will reduce and use the excess voltage), hence our choice of 2x Grape Solar 160W 12V solar panels.

As it turns out the use of two solar panels increases installation complexity, increases the number of parts required (and cost) and a PWM is not as efficient as a MPPT. If we were to do it again, we might consider a MPPT charge controller with only one solar panel (300W, 24V). That being said, we’re very confident with our setup. The Bogart Engineering SC-2030 is a neat charge controller and with 320W we have more power than we need.

 

INSPIRATION OF THE MOMENT

Drive Nacho DriveDid you ever have this wild dream of quitting your job and travel the world in a van? These guys had this dream, and went after it… very motivating reading!

Download the eBook from Amazon.

 

 

 

 

 

 

 

 

WANT MORE?

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ABOUT US

Hello! We’re Isabelle and Antoine, a couple dreaming of being on the move and we’re seeking for the ride of our life. We bought a Ford Transit van, we’re converting it to a campervan and we are now selling our house to make our dream a reality. We are sharing this in hope of inspiring and helping others to follow their dreams too!

 

 

CHEERS!

 

 

2 comments

  1. Comment by Chris

    Chris Reply February 26, 2017 at 11:51 pm

    Very detailed instructions! Thanks for the writeup. I did a very similar install on the roof of my 5th wheel about 1.5 years ago, also using the 3M VHB tape. I did end up losing one of 6 panels while on the highway somewhere in Arkansas… still don’t know where that panel ended up! As a result I installed a single screw in each of the Renogy mounts, and installed a wind-guard in front of the forward set of panels. I’ve since traveled 18,000 miles with all panels still attached. If you are interested in pictures of the wind guard, shoot me an email.
    Thanks for the great site and detailed descriptions!

    • Comment by Antoine

      Antoine Reply February 27, 2017 at 7:29 am

      You’re the first to report this. Thanks for letting us know! I think we will add screws, we don’t want to kill anybody…

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