Here's how I laid the 6mm2 solar cables from the van to the pop top.
I used 20mm flexible non-split conduit where the cable comes through the top of the light cluster held on to the bodywork with cable tie holders. I replaced the crap double sided tape on the holders with some proper foam tape made by Tesa.
A small hole was made in the light cluster grommet to thread the cables through. Then I used quick drying polyurethane sealant to give a good seal on it.
Routing the cables in the light cluster is quite tricky. It takes a bit of time to get it right. Basically you put a loop into the space below the light cluster and then the cables go to the left of the cluster as you look at the back of it. It takes a few goes to get it right.
The conduit goes up to the point shown on the bodywork. It stops just by the door hinge. The the cables are held on with another cable tie holder with just enough slack to enable them to move with the pop top opening and closing. The important thing is that they don't crease or kink when the roof is closed. They just gently flex which is fine.
Paint protection film was used on all points where cables or conduit may contact the bodywork to prevent paint rub.
Whilst it's not quite as tidy as being fully inside the van, I think it's a good option if you have had a pop top fitted and then decided to fit a panel. At least this way avoids any messing with already fitted carpet lining and trying to feed cables into difficult to access sections.
I used 20mm flexible non-split conduit where the cable comes through the top of the light cluster held on to the bodywork with cable tie holders. I replaced the crap double sided tape on the holders with some proper foam tape made by Tesa.
A small hole was made in the light cluster grommet to thread the cables through. Then I used quick drying polyurethane sealant to give a good seal on it.
Routing the cables in the light cluster is quite tricky. It takes a bit of time to get it right. Basically you put a loop into the space below the light cluster and then the cables go to the left of the cluster as you look at the back of it. It takes a few goes to get it right.
The conduit goes up to the point shown on the bodywork. It stops just by the door hinge. The the cables are held on with another cable tie holder with just enough slack to enable them to move with the pop top opening and closing. The important thing is that they don't crease or kink when the roof is closed. They just gently flex which is fine.
Paint protection film was used on all points where cables or conduit may contact the bodywork to prevent paint rub.
Whilst it's not quite as tidy as being fully inside the van, I think it's a good option if you have had a pop top fitted and then decided to fit a panel. At least this way avoids any messing with already fitted carpet lining and trying to feed cables into difficult to access sections.
