Dellmassive`s Camper Van Adventure

[Dellmassive]

Day #02.5 - the spare wheel bracket
sggsg

as it happens i didnt even need this, but we fitted it anyway.








but when we put the spare wheel back in it was loose and almost fell out.


so we had to take up the slack.

re drilling new holes. . .






and even that was too loose,






gave up in the end. . . for the standard wheel we had, even with the new RIB bracket we didnt need the spacer plate.


.

 

[Dellmassive]

Day #02.5 - the spare wheel bracket
sggsg

as it happens i didnt even need this, but we fitted it anyway.



View attachment 288766

View attachment 288767


but when we put the spare wheel back in it was loose and almost fell out.


so we had to take up the slack.

re drilling new holes. . .


View attachment 288768



and even that was too loose,

View attachment 288769

View attachment 288770


gave up in the end. . . for the standard wheel we had, even with the new RIB bracket we didnt need the spacer plate.

View attachment 288771
.

That was enough of that so we move on to the splashback and draws. . . .

all masked out, this is what i wanted..



cerbo screen, twin 240v CBE and twin 29mm USB chargers.



mark, drill, file - Bosh.




which gave us this. . .




+++

moving onto the draws, i OSMO`d all the bare wood ends. .



and soon found out that we needed to backout the draws,

as they would either rub on the floor, or not engage with the locking catch. . . 1mm spacers were needed, at the fronts.





adding both draws, , , ,






next up inverter fitting.

we opened it up to get to the 4x rear mounting holes.




then cut out the OEM side fibre panels and drilled in so PLY wood to act as a base to screw this super heavy inverter too.

the ply had a few good fixings.






and the shelf fitted with 2mm clearance - result.






next up was a wedding. . . . so the build got put on hold again.










.



TBC

 

[Dellmassive]

Loosing Coolant . . . . . !!!

did i mention, that after the Euro trip the low-coolant light com on. . .,

that's odd i thought, so i topped it up and carried on.

well imaging my surprise when a tank of diesel latter the same thing happened.

couldn't see a leak,
couldn't small a leak (coolant leak has a very distinctive sweet smell.

my instant gut feeling - EGR COOLER.

the van is still under ALL-IN warranty, so i started making my case & building evidence.


T6Forum - window sticker (reverse) in the sun





oooosh.








here you can see the drop in coolant from MAX to MIN over a tank of fuel,

id marked the tape with lines to see the drop.

three tanks, three drops, three marks - regular as clockwork.






++++++++++++++++++++++

T6 2017 90k – internal coolant leak, assumed EGR cooler?


Coolant will drop from FULL line to LOW line on every full tank of fuel,

Around 380-450 miles


No previous issues:

24/4/25 - Low coolant, checked -At min line,

24/4/25 - Topped up 500ml G12 coolant To top line.

24/4/25 – no visible external leak or smell of coolant from a leak, assumed internal leak

1/5/25 - Travel Europe trip,

10/5/25 – Low coolant warning, 460miles from last topup

10/5/25– no visible external leak or smell of coolant from a leak, assumed internal leak

10/5/25- topped up. . . . . 600ml G12+

18/5/25 – Low coolant warning, 390miles from last topup

18/5/25 - Topped up 500ml G12 coolant To top line.

5/6/25- low coolant

6/6/25 – van booked in with VW Chelmsford 92500ml

++++++++++++++++++++




got the van booked in for the above, a look what they gave us as a loaner , !!

Nice one VW Chelmsford.



it was only for the day - but Mrs Dellmassive loved it.



anyway . . .

surprise surprise, i get a call from the VW SA at Chelmsford,

he says thank your for the report we gave in a looks like we were correct - it needs a new EGR COOLER.

that's fine with me, as its a common thing on a T6,

and at 90K miles id say the EGR was well and truly due to be replaced.


hes doing the paperwork for the warranty claim and will get back to us.

a 1-2day job he said.




.

What's the problem then Dell . . . . . ?

we water being ingested into the engine is a big problem,

especially on a diesel,

water doesn't compress, or burn.

so unlike diesel, which is a liquid - that gets burnt in cylinder each stroke.

water wont burn, or compress. . . so it can hydraulic lock a cylinder/s. ( when there is enough volume )

best case it will blow out the head gasket.

worst case it will bend a conrod.

sure these are extreme results.

but water leaks just get worse with time, so the quicker you get on top of the problem - the better.





.

ill update this when the Bus is booked back in with them.


oh, they also said the rear breaks needed replacing - lol . . . Nah there fine mate, got loads left on them.

 

[Dellmassive]

did anyone else get the email?

VAN MATS FOR CAB FLOOR, SIDE STEPS & LIVING AREA | Volkswagen Transporter T5 to T6

Premium, heavy duty cab & side step mats with solid rubber non-slip backing to fit the VW T5 & T6. Other models also available. Fast Delivery. No Quibble Returns. We're Here to Help - 0113 804 2125.

www.kiravans.co.uk

.




i thought i would treat the BUS to some new mats.

both front door steps,
slider step,
side load area mid sized mat.

 

[Dellmassive]

what is it with S+S ?

every time i order, . . . . . nothing for two weeks, no coms, no delivery - nothing.

then i chase them,

then i get an email saying order getting posted.

just me?

ordered 24may25 !!

 

[Dellmassive]

Solar Panel. . . 180W (24.0v VOC, 9.22A ISC) Black, Mono, rear junction.





I've asked the pop-top installer to fit the panel. . .

I've included the install guide in the panel box,

and I've highlighted the install notes about FILLING IN THE ROOF RIDGES, to create a smooth surface (for equal thermal expansion across the panel)

and I've highlighted the bonding methods,

but really I'm in there hands, ill voice my concerns about the fitting. (but they will be, weve fitted loads of panels and never had one go wrong) - but we know better.


if you have a decent quality panel from a good manufacture, them im 90% sure the failures are down to poor fitting and not following the install guide, most noticeably "filling in the roof ridges" so you have one smooth surface.



++++++++++++++++++

Solar panel specifications:

• Peak power: 180W
• Maximum power voltage: 20.5V
• Maximum power current: 8.79A
• Open circuit voltage: 24.0V
• Short circuit current: 9.22A
• Dimensions: 1470 x 665 x 3 mm
• Weight: 3.15 kg

This product comes with a 3 year workmanship warranty which covers material and production defects. For more information please refer to our Terms and Conditions.

++++++++++++++++++

At Photonic Universe we love high quality solar products. That's why we have developed this highly durable black semi-flexible solar panel reinforced with fibreglass plastic and a strong ETFE surface and made from monocrystalline solar cells. This model also features a rear-fitted circular junction box and 3m dual core cable. This high efficiency 180W solar panel is perfect for permanent outdoor use to provide free electricity for charging 12V batteries to power various applications, such as in a motorhome, caravan, camper, boat, or for solar lighting systems, off-grid, and back up solar power systems. The panel can also be used to provide direct power supply for applications not sensitive to changes in input voltage / current (e.g. electric motors or pumps) and for various grid-tie applications.

Product features:

• Robust construction using plastic reinforced with glass fibre creates a sturdy and durable solar panel
• Special textured surface significantly reduces light reflection and improves performance in low light and cloudy conditions
• Highly flexible design makes this panel ideal for curved roofs and surfaces where bonding is preferable (though it can also be fixed by bolts or screws)
• The panel is incredibly light (only 3.15kg) and very thin (just 2mm) which is great for all vehicles
• High resistance to salt water environments makes it perfect for boats and marine applications
• Sealed waterproof design ensures it can be used in all weather conditions
• Junction box on the back allows for a smooth and level surface, free of trip hazards and unsightly cables. Round shape for easy fitting
• Fitted with a single length of high quality 3m dual core cable for easy installation and wiring

Strong ETFE coating:

In addition to the fibreglass reinforcement, the surface of this 180W semi-flexible solar panel is made of strong ETFE material which has a longer service life compared to standard semi-flexible solar panels. As a result, these particular semi-flexible solar panels are extremely hard-wearing and less prone to cracking, delamination and corrosion. The lightly textured coating of this panel creates an anti-reflective surface which allows the panel to absorb a far greater amount of light, thereby increasing efficiency. ETFE material has long been used in applications where durability and high-temperature resistance is required, such as in the Eden Project, Cornwall. You can read more about ETFE and its benefits here.

High quality 5-busbar solar cells:

This panel also features new generation 5-busbar solar cells, which are more efficient than the 2, 3 or 4 busbar solar cells used in most other solar panels, and are able to extract more power from the same surface area. This results in a smaller overall solar panel, which is ideal for applications where space is limited.

Simple, professional installation:

This particular model features the junction box and cable on the rear side of the panel to create a completely level surface and professional finish after installation. Unlike other solar panels, the junction box on this solar panel is a circular shape with only one dual core cable (3m length) attached, allowing for simplified installation. Please note: in order for this panel to be flush-mounted, a recess must be cut in to the roof/surface.

This solar panel has a unique black backing, making it ideal for discreet and aesthetically pleasing installation on dark coloured roofs, vehicles or mounting surfaces. Please note that this solar panel is not 'ultra jet-black' - the exact hue may vary marginally from panel to panel, depending on the batch of solar cells.

Anti-reflective textured surface:

The textured surface of this solar panel reduces the reflection of light whilst maximising the absorption of light from every possible angle. This ensures high performance in low light or cloudy conditions, or when the light falls at an angle (in the morning, evening, or winter).

Click on the Details and Specifications tab for more information about this product.


View attachment 276823View attachment 276824





View attachment 276825View attachment 276826View attachment 276828





++++++++++


View attachment 276830View attachment 276831



+++++++++++++



























.

View attachment 276827

View attachment 276829

Well I've decided to go bigger.....

Now it's a case of go big or go home.

530w to be more accurate.

https://www.photonicuniverse.com/upload/file/Manuals/MCS_certified_panels/FMCS-530M_datasheet.pdf

It's huge.

...




Now for the challenge of removing the the one that's stuck in there now.

I'm not happy with the way it's been fitted anyway..... So it's coming off.

The new one will be fitted:

With vinyl wrap on the paintwork, where anything sticky will be.

Then I'm going for VHB Velcro to the roofline ridges.

Tigerseal along the front edge, and probably down the sides..


Why Velcro?

Well the panel has 5yr warranty on a vehicle install , so that will make it easier to remove when the time comes.

It will allow the panel to move a bit with thermal expansion in the sun.

It will create a small air gap, to help keep the panel cooler.

.


I've ordered they vinyl wrap, tigerseal, Velcro.

.

Watch this space.


.
PMAX - 530w
VOC - 49.9v
ISC - 13.76A






++++++


edit:

this is what the 180w panel looks like atm.

 

[Dellmassive]

That was enough of that so we move on to the splashback and draws. . . .

all masked out, this is what i wanted..

View attachment 288775

cerbo screen, twin 240v CBE and twin 29mm USB chargers.

View attachment 288778

mark, drill, file - Bosh.


View attachment 288779

which gave us this. . .

View attachment 288780


+++

moving onto the draws, i OSMO`d all the bare wood ends. .

View attachment 288781

and soon found out that we needed to backout the draws,

as they would either rub on the floor, or not engage with the locking catch. . . 1mm spacers were needed, at the fronts.


View attachment 288782View attachment 288783


adding both draws, , , ,


View attachment 288784



next up inverter fitting.

we opened it up to get to the 4x rear mounting holes.

View attachment 288787


then cut out the OEM side fibre panels and drilled in so PLY wood to act as a base to screw this super heavy inverter too.

the ply had a few good fixings.


View attachment 288790



and the shelf fitted with 2mm clearance - result.

View attachment 288791




next up was a wedding. . . . so the build got put on hold again.


View attachment 288792

View attachment 288793View attachment 288794



View attachment 288795

.



TBC

wedding over,

it was time to move right into Spring camp.

another test run for the van and roof. . .




i decided i liked @Bigsidavies poptop LED lights. . .



the roof worked very well giving us much needed headroom.



a great time was had by all . .

 

[Dellmassive]

ELECTRICALS . . .


the 3kva bolted in well.



i kept the NEG as short as possible and made a new ground connection, using a flapper wheel to remove all the pain for a good connection.

we are expecting 300A plus to be going over this link - so it needs to be good.





next up was to re-do the seat base . .




i was using the seatbase at the main NEG. . . so removed all the paint from the 4x bolt holes.





this wire brush drill attachement worked a treat. .



the idea was to spread the NEG load across all four seat bolts.

we made up a new MEGA + MIDI main fuse box. - 70mm2 main feed into 400A main fuse.




and used 25mm2 for the smaller sub fuse boxes. . .







oh, by the way check out this awesome little Bluetooth lable printer.

cheap as chips and works brilliantly.


i loved it so much I've now got three - dont ask !!!!

https://amzn.to/3SH3jgo

+++++++++++++++

getting the battery back in i quickly realised that there wasn't enough room for all the kit i wanted in there. . .

i had loads of little blue boxes that needed to live somewhere.




+++++

so i decided to cur out the board benind the fridge and fit them in the void between the inner panels and outer skin of the van.


something i remember seeing years ago from @Deaky & @Fish when they fitted audio amps and stuff in the same space.




thats a piece of 9mm ply velcroed to the outer van skin, that i can now use small screws to hold in the MPPT + CERBO + Sub fuse box.


i managed to fit the twin RCBO 240v fuse box in there too.



a quick power-up and we have life.



happy days . . .



the shelf fits 2mm above the inverter. we then added a second double socket for the microwave that the cheif advisor wanted.

i left it on a floating lead as we didnt have a microwave yet.



.

later that day we done a quick test of the van furniture kitchen down lights. . .




.


thats it mad rush over.

this is what it was all in aid off.

the trip to Europe.


next stop France. . . .

 

[Sackmycook]

What's the plan for France ?

 

[Dellmassive]

ELECTRICALS . . .


the 3kva bolted in well.

View attachment 290702

i kept the NEG as short as possible and made a new ground connection, using a flapper wheel to remove all the pain for a good connection.

we are expecting 300A plus to be going over this link - so it needs to be good.


View attachment 290703


next up was to re-do the seat base . .

View attachment 290704


i was using the seatbase at the main NEG. . . so removed all the paint from the 4x bolt holes.

View attachment 290705



this wire brush drill attachement worked a treat. .

View attachment 290706

the idea was to spread the NEG load across all four seat bolts.

we made up a new MEGA + MIDI main fuse box. - 70mm2 main feed into 400A main fuse.

View attachment 290707


and used 25mm2 for the smaller sub fuse boxes. . .

View attachment 290708View attachment 290709

View attachment 290710



oh, by the way check out this awesome little Bluetooth lable printer.

cheap as chips and works brilliantly.


i loved it so much I've now got three - dont ask !!!!

https://amzn.to/3SH3jgo

View attachment 290712View attachment 290713


+++++++++++++++

getting the battery back in i quickly realised that there wasn't enough room for all the kit i wanted in there. . .

i had loads of little blue boxes that needed to live somewhere.


View attachment 290714

+++++

so i decided to cur out the board benind the fridge and fit them in the void between the inner panels and outer skin of the van.


something i remember seeing years ago from @Deaky & @Fish when they fitted audio amps and stuff in the same space.

View attachment 290715


thats a piece of 9mm ply velcroed to the outer van skin, that i can now use small screws to hold in the MPPT + CERBO + Sub fuse box.


i managed to fit the twin RCBO 240v fuse box in there too.

View attachment 290717

a quick power-up and we have life.

View attachment 290718

happy days . . .

View attachment 290719

the shelf fits 2mm above the inverter. we then added a second double socket for the microwave that the cheif advisor wanted.

i left it on a floating lead as we didnt have a microwave yet.

View attachment 290721

.

later that day we done a quick test of the van furniture kitchen down lights. . .


View attachment 290723

.


thats it mad rush over.

this is what it was all in aid off.

the trip to Europe.


next stop France. . . .

-- EURO TRIP --

it started at the channel tunnel.




the duty free was great. . .




we went on the train,



stayed at an AIRE in france,




went to Bruge,



done a boat trip . .



had RIBS & BEER.

went to the menin gate,



bought new Crocs



had belgium beers . .




see some war graves.




stayed at a french mansion place. . .




and even got to use the LOC8 table. . .


.

thanks guys for taking the time to show us how to do Europe. - looking forwards to the next trip.

@czmate1999
@Mick
@Bigsidavies
@Eli
@BoroBoy
@Dellmassive







. next stop was home bound.

 

[Dellmassive]

The next time the van was out was a Horsey day with the family.

-- Big POWER test --








we had the electric kettle running, the coffee machine, the airfryer, the microwave. . . the lot !!!









we was pulling some big power. . .




and started to notice that pulling 250-300A into the inverter we was getting some volt drop over the 70mm2 cable.

with the battery showing 12.5v, but the inverter showing 11.95v.

so ill need to double up and go twin 70mm2 or jump up to some 90mm2.


i also noticed that the Roamer 230sb battery, all though i can do the 300A output . . . . the internal BMS starts to get hot.

in this pic pulling 255A and the BMS temp is rising to 57C.

so on prolonged power runs we was triggering the high temp alarm.




leaving the inverter off load for a while quickly gets the battery temp back down again.





+++++++++

so what i plan to do is to add in a second Roamer 230SB battery under the second seat.

that will give me extra capacity - doubling to 460ah.

but also halfling the power draw so its split over the two battery's. . .

150A + 150A - that will help keep the battery's BMS cool while pulling full loads for extended durations.


ill also upgrade the main INVERTER feeds by doubling the 70mm`s or going 90mm2.

ill see as its fat beefy cable already.


in all fairness the VICTRON manual clearly states that 0-5m runs should be 90mm2 or twin 70mm`s . . . . . i just thought 70mm2 would be enough for the peak loads.

but the volt drop is clearly an issue.

i might try fitting the second battery first. . . . . . and then re-test, to see what effect that has.


then if needed ill upgrade the power feeds to the inverter.






.

 

[Dellmassive]

that basically bring us upto date.

the new 530w solar panel has arrived.

just waiting on fitting stuff for that.

. . .

the roamer battery is due in this month,

...

we have a sleep over in the van in a couple o weeks.

+++


then its camper jam !!!!!!


so lets see what we can get done before that.



plus we have the EGR cooler that needs replacing at VW.

 

[Dellmassive]

How big are you going?
I bought a 270W photovoltaic Universe panel with rear gland / cable entry, am now thinking I don't want to cut such a big hole in the pop top so will look for one with top cable connections.

finally got it sorted out.

im going as big as i can go - 530w in one panel.

its arrived (on two pallets lol - truck delivery)

hopefully it fits ok.

Post in thread 'Dellmassive`s Camper Van Adventure'

8 Jun 2025

Solar Panel. . . 180W (24.0v VOC, 9.22A ISC) Black, Mono, rear junction.





I've asked the pop-top installer to fit the panel. . .

I've included the install guide in the panel box,

and I've highlighted the install notes about FILLING IN THE ROOF RIDGES, to create a smooth surface (for equal thermal expansion across the panel)

and I've highlighted the bonding methods,

but really I'm in there hands, ill voice my concerns about the fitting. (but they will be, weve fitted loads of panels and never had one go wrong) - but we know better.


if you have a decent quality...

• Dellmassive

• 
• 
• 

.





its definately big. . . .







but looks like it should fit on the roof fine.

 

[Skyliner33]

finally got it sorted out.

im going as big as i can go - 530w in one panel.

its arrived (on two pallets lol - truck delivery)

hopefully it fits ok.

Post in thread 'Dellmassive`s Camper Van Adventure'

8 Jun 2025

Solar Panel. . . 180W (24.0v VOC, 9.22A ISC) Black, Mono, rear junction.





I've asked the pop-top installer to fit the panel. . .

I've included the install guide in the panel box,

and I've highlighted the install notes about FILLING IN THE ROOF RIDGES, to create a smooth surface (for equal thermal expansion across the panel)

and I've highlighted the bonding methods,

but really I'm in there hands, ill voice my concerns about the fitting. (but they will be, weve fitted loads of panels and never had one go wrong) - but we know better.


if you have a decent quality...

• Dellmassive

• 
• 
• 

.


View attachment 290808


its definately big. . . .




View attachment 290809View attachment 290810


but looks like it should fit on the roof fine.

View attachment 290811

Wow, nice. Are you just going to stick it on top of the other?
I’m cussing that’s just placed for size and the gland will go at the rear when fitting?

 

[Dellmassive]

Wow, nice. Are you just going to stick it on top of the other?
I’m cussing that’s just placed for size and the gland will go at the rear when fitting?

No. I going to remove that old one with string, plastic scraper and some wd40.

Then final wrap the sections that I'm going to put the velcro or tiger seal on.

I'll be using vhb 3M velcro on the ridges, I'll leave the troughs open for ventilation.

Then I will tiger seal along the front edge and down the left hand right hand side leaving the back open.

The plan is to allow enough movement for thermal expansion so when as the panel heats up and gets hot and cools down it will expand evenly and not cracked the buzz bars..... That's what normally fowls on these panels.... The velcro should have enough movement.

And the tiger is a polyurethane based stuff that is ravery and again should allow for some movement.

 

[EAN]

No. I going to remove that old one with string, plastic scraper and some wd40.

Then final wrap the sections that I'm going to put the velcro or tiger seal on.

I'll be using vhb 3M velcro on the ridges, I'll leave the troughs open for ventilation.

Then I will tiger seal along the front edge and down the left hand right hand side leaving the back open.

The plan is to allow enough movement for thermal expansion so when as the panel heats up and gets hot and cools down it will expand evenly and not cracked the buzz bars..... That's what normally fowls on these panels.... The velcro should have enough movement.

And the tiger is a polyurethane based stuff that is ravery and again should allow for some movement.

Looking forward to seeing you do this: Not sure what possessed them to only put 0.3M of cable on that panel though!!

 

[Dellmassive]

did anyone else get the email?

VAN MATS FOR CAB FLOOR, SIDE STEPS & LIVING AREA | Volkswagen Transporter T5 to T6

Premium, heavy duty cab & side step mats with solid rubber non-slip backing to fit the VW T5 & T6. Other models also available. Fast Delivery. No Quibble Returns. We're Here to Help - 0113 804 2125.

www.kiravans.co.uk

View attachment 290557


.




i thought i would treat the BUS to some new mats.

both front door steps,
slider step,
side load area mid sized mat.


View attachment 290558

These arrived . . . . but one door step matt is missing


jeez - you just cant get the staff these days.

a quick email to KIRAVANS has them sending out the missing item.

 

[Dellmassive]

finally got it sorted out.

im going as big as i can go - 530w in one panel.

its arrived (on two pallets lol - truck delivery)

hopefully it fits ok.

Post in thread 'Dellmassive`s Camper Van Adventure'

8 Jun 2025

Solar Panel. . . 180W (24.0v VOC, 9.22A ISC) Black, Mono, rear junction.





I've asked the pop-top installer to fit the panel. . .

I've included the install guide in the panel box,

and I've highlighted the install notes about FILLING IN THE ROOF RIDGES, to create a smooth surface (for equal thermal expansion across the panel)

and I've highlighted the bonding methods,

but really I'm in there hands, ill voice my concerns about the fitting. (but they will be, weve fitted loads of panels and never had one go wrong) - but we know better.


if you have a decent quality...

• Dellmassive

• 
• 
• 

.


View attachment 290808


its definately big. . . .




View attachment 290809View attachment 290810


but looks like it should fit on the roof fine.

View attachment 290811

Right come on - i know you are all waiting for this one, thets do this.


-- 530W solar panel install -

this this is huge !!

but the first problem was getting the old one off.

i tried a multi angled attack, as the panel is still new so i wanted to remove it carfully to re-use / sell on.






a combination of plastic scrapers, metal scrapers . . which worked well for the outer edges, but couldn't get to the inner ribs.



for those we needed the cheese-wire technique.

but using cotton / string / fishing line. which all snapped.

so ended up using 8lengths of gazebo repair HD nylon thread stuff, to saw through. - i had the chief advisor to help.




and it was finally off.





using a plastic blade scraper we got the bulk off, which left us with this mess. . . .






this balls up ladies and gentlemen is exactly why you need to put down vinyl wrap before sticking anything to the paintwork.

a quick google about Tiger seal / Sikaflex showed us that it was Polyurethane based.

chemicals to remove it were listed as.

isopropyl alcohol
acetone
nail varnish remover
WD40
Brake clean

we tried the lot, the weak stuff didnt touch it, the strong stuff started to melt the paintwork.


the next day i order more supplied to tackle the job.




the Toffee wheels done the best job after the plastic scraper. . . i though that they would burn the paintwork - but didnt.




it was slow going for sure.





kit list:


Scraper tool plastic - https://amzn.to/3HDrRod
Metal tool - https://amzn.to/3SR0SYI
Plastic blade kit - Amazon.co.uk
Toffee wheel 1 - https://amzn.to/4kJucN8
Toffee wheel 2 - https://amzn.to/43USz33








.

 

[Dellmassive]

Right come on - i know you are all waiting for this one, thets do this.


-- 530W solar panel install -

this this is huge !!

but the first problem was getting the old one off.

i tried a multi angled attack, as the panel is still new so i wanted to remove it carfully to re-use / sell on.



View attachment 291613


a combination of plastic scrapers, metal scrapers . . which worked well for the outer edges, but couldn't get to the inner ribs.

View attachment 291614

for those we needed the cheese-wire technique.

but using cotton / string / fishing line. which all snapped.

so ended up using 8lengths of gazebo repair HD nylon thread stuff, to saw through. - i had the chief advisor to help.

View attachment 291615


and it was finally off.


View attachment 291616


using a plastic blade scraper we got the bulk off, which left us with this mess. . . .

View attachment 291617




this balls up ladies and gentlemen is exactly why you need to put down vinyl wrap before sticking anything to the paintwork.

a quick google about Tiger seal / Sikaflex showed us that it was Polyurethane based.

chemicals to remove it were listed as.

isopropyl alcohol
acetone
nail varnish remover
WD40
Brake clean

we tried the lot, the weak stuff didnt touch it, the strong stuff started to melt the paintwork.


the next day i order more supplied to tackle the job.

View attachment 291618


the Toffee wheels done the best job after the plastic scraper. . . i though that they would burn the paintwork - but didnt.

View attachment 291619


it was slow going for sure.


View attachment 291620


kit list:


Scraper tool plastic - Amazon.co.uk
Metal tool - Amazon.co.uk
Plastic blade kit - Amazon.co.uk
Toffee wheel 1 - Amazon.co.uk
Toffee wheel 2 - https://amzn.to/43USz33








.

moving on . . .

we masked out the new panels outline.



and got the wrap out. . .

we went for this stuff as advised by the resident Vinyl expert @Grim Reaper who recommended this stuff.

not cheap, but versus a roof repaint it was worth it.

it come as 152cm by whatever - we opted for 2m.

https://www.mdpsupplies.co.uk/vehicle-wrapping/kpmf-vws-premium-matt-cast-vinyl

well - i have to say i have a new found respect for anyone that does vinyl wrapping.

this stuff is like plastering - it looks easy to do, but dont let the videos fool you.

its a pain in the bum . . . it took two of us ages and a few choice words.

we ended up with creases, bubbles, stretches - you name it.

luckily 90% of this will be hidden under the new panel anyway, disaster avoided.



the plan was to put vinyl down anywhere any sticky stuff went.. . . .

so that's what we did, I'm planning on using VHB Velcro to stick the panel to the roof.

this will allow:

A - easier removal in future as it has a 5yr warranty
B - allow for better thermal expansion of the panel, ie it can breath with the heat
C - less damaging to the van
D - let the panel run cooler as it has air around it.


out with the Velcro then. - i had the 50mm stuff that i use all the time,

i got a 10m role, and used what's left of the 5m role.

hook side on the roof,

loop side towards the panel.

them we are planning on a Tigerseal bead across the front lip and possibly don the sides,

and definitely leaving the back side fully open.






we used coke cans to hold the panel up off the roof while it was lined up.....

this stuff is SUPER sticky !!!! trust me.







with a bead of tigerseal along the front, and a couple of bricks to weigh down the corners over night we was done.




kit used:

Tube Gun - Amazon.co.uk
VHB Velcro - https://amzn.to/3HWi9gH
Tigerseal - https://amzn.to/4l6mht1
masking tape - Amazon.co.uk

.

 

[Velosaurus]

Very good explanation. Gives me confidence to tackle mine later this year. (Edit: Next post answers my question)