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post #1 of 3 (permalink) Old 16-10-2011, 18:47 Thread Starter
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Solar Panel Fitting

For this task
You'll need some aluminium angle 60mm x 40mm x 3mm x 1 metre or equivalent
set square
tape measure
rivet gun
4mm rivets
4mm hss drill bit
5mm tap
5mm set screws

This is the third set of brackets I've made so far. I've used 60mmx40mmx3mm angle as I came by it handy like
A metre length of this stuff or similar can usually be bought for under a tenner, Ebay is good for this but plus P&P
Closest I've found is 2.5"x1.5"x1/8" x1M for about 14 delivered.
Previously I've fitted 60 watt and 80 watt panels which require 4 brackets each and so only 1 set screw needed for each one. In this instance I've made brackets for 2 x 30 watt panels that will only require 1 bracket at each end and so I've fitted 2 set screws to keep them level. These are 5mm and I used a 4mm hss drill bit followed by a 5mm tap both driven through using a battery drill. You can use anything similar to achieve this or just a spacer.
Sikaflex 512 adhesive requires a MINIMUM thickness of 2mm and the set screws guarantee this will be acheived. I use the thickness of the brackets 3mm as in picture 3 to guage this.
These particular brackets are 200mm long and the panel ends (to be illustrated next) are 445 mm wide.

Attaching to the panels to follow...........

These brackets are being used on 2x30watt panels. The reason for using this configuration rather than a 60 watt is purely due to space constraints.
These measure only 445 wide by 540 long so will fit in the narrow stip between the sun roof and the van edge.
pic 1 a bracket drilled and riveted to a panel end. I use rivets because they wont come undone but can be easily drilled out should a panel need replacing.

pic 2 panels laid out simulating how they will be on the roof

pic 3 male & female branch connectors to couple the 2 panels in parallel ready to go to regulator or another panel


Continued in PART II

You will need these plus Sikaflex adhesive (512) and cartridge gun

Position panels and mark the footprints of the brackets

Clean the areas and underside of brackets with Sikaflex 205 cleaner primer

Adjust set screws to give a MINIMUM of 2mm spacing I prefer 3 to 4mm

Apply plenty of adhesive

Position panels and press down firmly

Clean off excess and smooth off

Leave overnight to set

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Excusez-moi si mon message est perdu dans la traduction
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post #2 of 3 (permalink) Old 26-10-2014, 09:10
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This is a great step by step guide.
Did you have to drill the roof or did you feed the cable via and existing route?
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post #3 of 3 (permalink) Old 26-10-2014, 09:50
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On my motorhome they are fitted similar to this with one exeption the panel that can be reached from the sky light is fitted with a hinge on the far side therefore the panel can be raised and the terminal box etc. are below.
This makes it very easy to check things out and if in parked in the correct position it's possible to prop it up for better receiving the sun rays.
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