Mounting Solar Panels and Water-proofing roof entry for wires

[LivingandLearning]

I am just about ready to buy a 300-watt solar system and roof rack.  I had a couple of questions about installing them:

1.  Can I mount them directly to the roof rack or do I need to mount them on plywood?  What is the best way you've seen to mount the panels?  I normally don't drive more than 70mph.  ps i was going to buy the Werner racks from Lowes--they have square bars, but there are cheaper ones on Craigslist that have round bars.

2.  What is the best way to take the wires through to the inside of the van?  I have a Ford e350 extended passenger van.  I once saw someone use some kind of box that was waterproofed and allowed easy work on the wiring.

Any other advice you might have would be greatly appreciated!

Tracy

 

[TMG51]

Who was it here that used some water tight connectors on the roof of his van to pass the wires through? I can't remember. Someone else probably will know what I mean. That was a pretty tidy install job.

I personally just used caulking. I had a leak shortly after, and realized it was because I had ran both wires tightly into the same hole - water was flowing between the two wires! I sealed it but if I were to do it again I would have one hole for each wire...

Could always grab a couple of UFC romex connectors from the hardware store if you aren't worried about looks.

 

[Canine]

I always just drilled a hole where I needed it and sealed it with caulk.Use the $4 caulk,not the $2 stuff.If you ever want to remove the wiring,a plow bolt with a painted head will cover the hole nicely.

 

[GotSmart]

This is how I did it.

https://vanlivingforum.com/Thread-Renogy-rooftop-installation-using-racks

The wires went in through the side of my Fantastic fan.

 

[Optimistic Paranoid]

You didn't say whether you were mounting multiple panels or a single large 300 watt panel.  The box type things are usually used for multiple panels for convenience - you only need to run a couple of wires from the box through the roof.  If one big panel, don't bother with the box.  I'm planning on using THESE for my system, there are different part numbers for different size wires.

http://www.amazon.com/gp/product/B000NI019O?psc=1&redirect=true&ref_=oh_aui_detailpage_o03_s00

Regards
John

 

[LivingandLearning]

You didn't say whether you were mounting multiple panels or a single large 300 watt panel.  The box type things are usually used for multiple panels for convenience - you only need to run a couple of wires from the box through the roof.  If one big panel, don't bother with the box.  I'm planning on using THESE for my system, there are different part numbers for different size wires.

http://www.amazon.com/gp/product/B000NI019O?psc=1&redirect=true&ref_=oh_aui_detailpage_o03_s00

Regards
John

John, I'm going to go with three Renogy panels http://www.amazon.com/gp/product/B0...t solar kit&qid=1446870152&ref_=sr_1_3&sr=8-3  It looks like they combine to two wires coming through the roof.  I just don't want it to leak.  Thanks for the link.  That looks very useful.

 

[LivingandLearning]

This is how I did it.

https://vanlivingforum.com/Thread-Renogy-rooftop-installation-using-racks

The wires went in through the side of my Fantastic fan.

Thanks for linking this!  I hadn't thought of using angle iron or whatever you call those long L pieces.  I was trying to figure out how to mount to square poles.  This would be perfect AND relatively easy.

Tracy :shy:

 

[GotSmart]

Thanks for linking this!  I hadn't thought of using angle iron or whatever you call those long L pieces.  I was trying to figure out how to mount to square poles.  This would be perfect AND relatively easy.

Tracy :shy:

That is aluminum angle.  Standing next to the van, you have a hard time telling there is a solar panel there.  

Once things are marked, remove the roof racks to drill and mount the angle.

 

[SternWake]

That is aluminum angle.  Standing next to the van, you have a hard time telling there is a solar panel there.  

Once things are marked, remove the roof racks to drill and mount the angle.

When i got my framed Kyocera 130 watt panel in 2007, I made a Mock solar panel from 2x2's and Laid it on my roof, then made some corner "feet" from plywood and Some IPE wood.

I ground these feet to fit the curve of the roof, then sanded down through paint and Gelcoat and used polyester resin to adhere them in place and used  Fiberglass to cover the wood. then painted over it.
I can tilt the panel 90 degrees toward either side of the Van, but almost never tilt it at all.
I used cord grips for the wire pass through.

http://www.amazon.com/Arlington-LPC...446939198&sr=8-1&keywords=cord+grip+connector

It can tilt on the Stainless steel clevis Pins that I installed in the frame using angle aluminum and rivets to hold them in place at 90 degrees.

Tested to 100MPH

 

[BradKW]

Saw this... off the shelf of Home Depot for components...

[img=440x330]https://handybobsolar.files.wordpress.com/2012/04/img_4405.jpg?w=880&h=660[/img]

 

[BigT]

I am just about ready to buy a 300-watt solar system and roof rack.  I had a couple of questions about installing them:

1.  Can I mount them directly to the roof rack or do I need to mount them on plywood?  What is the best way you've seen to mount the panels?  I normally don't drive more than 70mph.  ps i was going to buy the Werner racks from Lowes--they have square bars, but there are cheaper ones on Craigslist that have round bars.

I have a Yakima with the round crossbars and I mounted the panel directly to the bars using u-bolts.  It was easy. 

Can't really help you with running the wires.  The Ford Transit Connect comes with multiple holes already in various places on the body, with grommets in them.  

U-bolts are my fastener of choice on my van.  I use them for just about everything, as is evident in this photo.  

If you look closely you can see the u-bolts holding the panel in place in this picture.