DIY solar installation

[Efficacious]

HI all,

I just came across this thread and having done a very similar job thought that it may be useful to add photos of my panel installation. It is a 200W single panel (Allpowers) which by positioning it asymmetrically across the roof rails towards the awning side fits in nicely.

I used some aluminium strips across the roof and bonded to the panel with U extrusion end caps. It is secured by drilling through the panel and strips and use of M6 T nuts. I also used neoprene strips to pad from the roof. The finished assembly is nice and solid with no wind noise or vibration.

I created my own curly cable by winding some 12AWG 2 core cable tightly around a pole. I secured it with tape and left it in the warm sun for a couple of days, then steamed it for good measure. It held the shape nicely when I removed it and after a month or so and a bit of roof use now shows no sign of loosing the coil/shape. Cost £10.

The junction box was a bargain - quoted as being IP68 rated and 2 for £6.99 from Amazon. I removed the MC4 connectors from the panel wiring and solder joined to the curly cable inside the box.

 

[Ads1234567890]

Thanks almost bought a California used your detailed info 2 panels installed I used the mc4 plugs but crimped Solar to curly flex

 

[Van Diesel VW]

Thank you all for this really helpful thread, after some thought decided to go down the DIY route for solar on my California, mainly cost reasons, but also learning and flexibility of install. Currently managed to purchase 2 x Renogy 100w panels for £75 each in Black Friday offers.

100W Solar Panels for Campervan,Solar Panels UK|Renogy

The Renogy 100W Flexible Lightweight Solar Panel enhances module efficiency while minimizing its weight.It is the perfect solar panels for campervan.

uk.renogy.com

First question is cable size from panels to MPPT controller, will use 4mm cable from MTTP to battery, do I also need 4mm from panels to MPPT or is 2.5 mm cable adequate, highly unlikely that I will add anymore panels in the future.

 

[Efficacious]

Thank you all for this really helpful thread, after some thought decided to go down the DIY route for solar on my California, mainly cost reasons, but also learning and flexibility of install. Currently managed to purchase 2 x Renogy 100w panels for £75 each in Black Friday offers.

100W Solar Panels for Campervan,Solar Panels UK|Renogy

The Renogy 100W Flexible Lightweight Solar Panel enhances module efficiency while minimizing its weight.It is the perfect solar panels for campervan.

uk.renogy.com

First question is cable size from panels to MPPT controller, will use 4mm cable from MTTP to battery, do I also need 4mm from panels to MPPT or is 2.5 mm cable adequate, highly unlikely that I will add anymore panels in the future.

I used 2 core 12AWG cable (3.3mm^2) which is easily adequate with my 200W and would allow a further 200W if we needed it.

The current Amazon price of £6.89 for 2m is actually a good bit less than I paid earlier in the year.

https://www.amazon.co.uk/dp/B0B7WNS21H?tag=unique09f-21

 

[Almost bought a california]

HI all,

I just came across this thread and having done a very similar job thought that it may be useful to add photos of my panel installation. It is a 200W single panel (Allpowers) which by positioning it asymmetrically across the roof rails towards the awning side fits in nicely.

I used some aluminium strips across the roof and bonded to the panel with U extrusion end caps. It is secured by drilling through the panel and strips and use of M6 T nuts. I also used neoprene strips to pad from the roof. The finished assembly is nice and solid with no wind noise or vibration.

I created my own curly cable by winding some 12AWG 2 core cable tightly around a pole. I secured it with tape and left it in the warm sun for a couple of days, then steamed it for good measure. It held the shape nicely when I removed it and after a month or so and a bit of roof use now shows no sign of loosing the coil/shape. Cost £10.

The junction box was a bargain - quoted as being IP68 rated and 2 for £6.99 from Amazon. I removed the MC4 connectors from the panel wiring and solder joined to the curly cable inside the box.

View attachment 137014

View attachment 137015

View attachment 137016

Love the curly cable - considerably cheaper than mine and it looks great!

 

[Almost bought a california]

Thank you all for this really helpful thread, after some thought decided to go down the DIY route for solar on my California, mainly cost reasons, but also learning and flexibility of install. Currently managed to purchase 2 x Renogy 100w panels for £75 each in Black Friday offers.

100W Solar Panels for Campervan,Solar Panels UK|Renogy

The Renogy 100W Flexible Lightweight Solar Panel enhances module efficiency while minimizing its weight.It is the perfect solar panels for campervan.

uk.renogy.com

First question is cable size from panels to MPPT controller, will use 4mm cable from MTTP to battery, do I also need 4mm from panels to MPPT or is 2.5 mm cable adequate, highly unlikely that I will add anymore panels in the future.

Hi Mr Diesel, I used a 4 core 2.5mm2 cable between the solar panel and the controller and used 2 cores for both pos and neg - 1.5mm2 would be OK for the current from a 200W panel but 2.5mm2 would give a safety margin and less volts drop when the suns out. I only used a 4 core cable because I expect I'll add a 2nd panel at some point and I wanted the option to connect both in parallel and series - probably over the top and it made the curly cable a lot more expensive!
I have a 15A MPPT controller and soused 2.5mm2 cable between this and the rear battery but your choice will depend on max current, cable type and cable length - Chat GPT will give you an accurate answer.

 

[Almost bought a california]

Thanks almost bought a California used your detailed info 2 panels installed I used the mc4 plugs but crimped Solar to curly flex

View attachment 139884

Very nice work!

 

[Carl_______________]

This guy on eBay makes the cables up to whatever your specification requirements are

4 CORE 1.5sqmm COILED BLACK LSZH 13amp POWER CABLE. 500mm (20") COIL LENGTH # | eBay UK

500mm (20") Black Coiled 13amp Power lead. This is a 4 core 1.5sqmm flexible spiral LSZH H05Z1Z1-F cable. Due to the bend in the black cable, these may appear grey. Coil length of approx.

ebay.us

I have had a couple of different sizes made up, the 4c 2.5mm is a Chucky cable

 

[Feggers]

Just finished installing a 100W solar panel and thought there might be some interest in a DIY option - I did see the post by MCEv (Moxie) asking for experience of the Solar Campers Solution but didn't want to hijack his post as the DIY route won't be for everyone and by all accounts the Solar Campers Solution is very good if you want a ready to fit kit.
Total price was just under £300 so not cheap! I loved the Califaktur solar module and the AMAG solution but the prices were way out of my reach and so got a local sheet metal firm to fold a mounting panel for me. I managed to find a suitable curly cable for under £20 but after ordering the solar panel and the controller I discovered that the company only had orange cables in stock so I had to get a one off made at great expense by a super helpful company in Ireland (£61 after carriage and taxes!)

View attachment 134494
I order to keep the roof neat I had to chop the plugs off the solar panel - I did test it first but needless to say I suspect this will negate any warranty LOL

View attachment 134495
I opted of a 100W Renogy panel and it was giving 50W here at 5:00 on an April evening so happy with that!

View attachment 134496
I expected the cable route would be straight forward - it was in the end but the back end is double skinned and so it didn't end up taking the expected route.

View attachment 134497

I opted for the 75v, 15W controller incase I fit more panel(s). still overkill I suspect but it's a very nice bit of kit and has an App to monitor and log the solar and battery parameters.

Happy to share the panel mount drawing if anyone else fancies having a go ;-)

Hell do you know wieght of all tat on the roof ? had no problems with the hydraulics ? thanks