For this task
You'll need some aluminium angle 60mm x 40mm x 3mm x 1 metre or equivalent
4mm hss drill bit
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
USING MC4 CONNECTORS
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