Solar Panel fail

[Drive Wayne]

Thanks CT, still planning to remove mine and pursue a warranty claim. It will also mean 8kg less weight on pop top and van. Plan to use combo of windscreen cheese wire, bread knife etc & clean up with toffee wheel. Put something like PPF down if still unsightly.

Need to do more research on rigid panel mounting that suits my Skyline poptop. Not sure if thats brackets or side roof bars. Roof bars would mean am not drilling solar panel size specific holes in roof & spread load better. Will also make panel replacement much more straight forward if failure happens.

Warranty & supplier CS record will be a key decider when buy replacement panel. Will also work out what everything weighs and test weight on pop top before commit.

Yeah its a job for warmer weather...

PU sent me a replacement panel under warranty without me needing to remove my failed one. Just a picture of the barcode and delaminating bits was enough for them to send me a replacement panel, which I didnt fit and went all rigid! No regrets, just have to be careful under 2m barriers...

 

[Creamytash]

Thanks CT, still planning to remove mine and pursue a warranty claim. It will also mean 8kg less weight on pop top and van. Plan to use combo of windscreen cheese wire, bread knife etc & clean up with toffee wheel. Put something like PPF down if still unsightly.

Need to do more research on rigid panel mounting that suits my Skyline poptop. Not sure if thats brackets or side roof bars. Roof bars would mean am not drilling solar panel size specific holes in roof & spread load better. Will also make panel replacement much more straight forward if failure happens.

Warranty & supplier CS record will be a key decider when buy replacement panel. Will also work out what everything weighs and test weight on pop top before commit.

Yeah its a job for warmer weather...

I just want to say a quick thank you, you have caused me to question/reconsider my options ref method of mounting a rigid solar panel. To that end I have been looking at the option of fitting roof rails with cross bars to take a rigid panel but the jury is still out.
CT.

 

[Velosaurus]

I just want to say a quick thank you, you have caused me to question/reconsider my options ref method of mounting a rigid solar panel. To that end I have been looking at the option of fitting roof rails with cross bars to take a rigid panel but the jury is still out.
CT.

Thanks CT, I am very grateful for this thread, as it convinced me to consider a rigid panel. Also many thanks for me joining in as its helped a lot. I have been churning this in my mind since I realised my existing panel was borked in July.

I think I am almost convinced on a rigid panel. Roof bars just seem a way to future proof against future replacement and are also designed to spread the load on a pop top. I took out all my furniture in the summer when I upgraded to lithium and added some additional furniture and it convinced me that anything fitted needs to be easy and quick to remove/modify/replace.

Just as well as planning now to take it all out again in the spring to replace the Van furniture back panel which I dont like, replace the curtains with blinds and remove the Smev gas cooker and replace with an induction hob and Bluetti downstream of the main lithium LB.

 

[Velosaurus]

PU sent me a replacement panel under warranty without me needing to remove my failed one. Just a picture of the barcode and delaminating bits was enough for them to send me a replacement panel, which I didnt fit and went all rigid! No regrets, just have to be careful under 2m barriers...

Thanks good to know about PU, although this was bought from a reseller, and was a stock substitute for the 180w I ordered, so might not even be a PU panel (naive me should have checked).

The highest thing on my van is actually the Fiamma awning. I am also getting the original factory springs re-fitted this year which will make it 40mm higher (original owner fitted lowered springs and now its converted the ride is way too low & harsh). I actually don't know the overall height as I dont go near height barriers

 

[Drive Wayne]

Thanks good to know about PU, although this was bought from a reseller, and was a stock substitute for the 180w I ordered, so might not even be a PU panel (naive me should have checked).

The highest thing on my van is actually the Fiamma awning. I am also getting the original factory springs re-fitted this year which will make it 40mm higher (original owner fitted lowered springs and now its converted the ride is way too low & harsh). I actually don't know the overall height as I dont go near height barriers

Don't mention where you bought it from, I wasn't asked, but from the bar code and receipt date they were good enough to send me a replacement. It was the guys at @AJCConversions that told me about the delamination issues.

 

[Creamytash]

Thanks CT, I am very grateful for this thread, as it convinced me to consider a rigid panel. Also many thanks for me joining in as its helped a lot. I have been churning this in my mind since I realised my existing panel was borked in July.

I think I am almost convinced on a rigid panel. Roof bars just seem a way to future proof against future replacement and are also designed to spread the load on a pop top. I took out all my furniture in the summer when I upgraded to lithium and added some additional furniture and it convinced me that anything fitted needs to be easy and quick to remove/modify/replace.

Just as well as planning now to take it all out again in the spring to replace the Van furniture back panel which I dont like, replace the curtains with blinds and remove the Smev gas cooker and replace with an induction hob and Bluetti downstream of the main lithium LB.

Can't remember if you said you have a pop top. I have a pop top. I am pondering at the re roof rails and cross rails as to how I am going to secure the rigid solar panel to the cross bars. Once we get back to normal on Monday I am seriously going to start looking at options by going.at looking at stuff in the flesh but I am still inclined towards roof rails and cross bars. Van Style do a set of roof rails with 3 cross bars, most only come with 2 cross bars.

 

[Velosaurus]

Yes I have a Skyline PopTop fitted to my T5.1 in 2022. I did a quick search a few months ago and there are some good threads on here and the old T5 forum. Some Youtube content as well. If I go down the rigid/roof bar option, which is likely, I would like the panel to sit no higher than the top of the side rails. I dont know yet how to implement that and whether the panel will need 4 or 6 fixing points. Apologies, I wont get time to fully research until Feb at the earliest.

 

[DXX]

However it’s installed I would allow for some thermal expansion with the mountings.

 

[Stay Frosty]

If I had a low profile pop top I wouldn't have roof rails or a rigid panel and would probably go down some sort of suitcase folding or draped panel set up as an alternative to simply replacing the Flexi panels/s.
We're going into year 4 with our two Renogy 175 watt panels so may just be lucky but given the amount of choice available I would probably copy Lee and fit a snooker table sized single panel for sleek minimalist looks and decent output.

 

[Velosaurus]

However it’s installed I would allow for some thermal expansion with the mountings.

thermal expansion of the physical rigid panel? Any idea how much please?

 

[DXX]

thermal expansion of the physical rigid panel? Any idea how much please?

No idea but you can measure it cold and measure it hot.
I would think that neoprene or high modulus frame sealant would be flexible enough.

 

[Creamytash]

Yes I have a Skyline PopTop fitted to my T5.1 in 2022. I did a quick search a few months ago and there are some good threads on here and the old T5 forum. Some Youtube content as well. If I go down the rigid/roof bar option, which is likely, I would like the panel to sit no higher than the top of the side rails. I dont know yet how to implement that and whether the panel will need 4 or 6 fixing points. Apologies, I wont get time to fully research until Feb at the earliest.

I am going to Vanstyle in person on Monday(30 mins from me) to look at the cross bars that come with their rails. If the cross bars have a slot in them that will accept 'T' head bolts and if I can invert the cross bars so the slot is underneath rather than on top and they will still fit on the roof rails that way I will intend to invert the cross bars then fit the solar panel brackets to the solar panel then using T head bolts into slot in the inverted cross bars I will mount the panel underslung on the cross bars rather than sat on top of the roof bars. I hope that makes sense. I intend to do the job sooner than later so if my idea works out I will take plenty of photos and post then for you to consider. My main reason for mounting the solar panel on roof bars is that solar panels sizes are irregular and if the next one fails and I have bracketed it to the roof I could finish up with holes drilled all over the roof where as on roof bars I can easily adjust to accomodate for a different size of panel.

 

[Drive Wayne]

I am going to Vanstyle in person on Monday(30 mins from me) to look at the cross bars that come with their rails. If the cross bars have a slot in them that will accept 'T' head bolts and if I can invert the cross bars so the slot is underneath rather than on top and they will still fit on the roof rails that way I will intend to invert the cross bars then fit the solar panel brackets to the solar panel then using T head bolts into slot in the inverted cross bars I will mount the panel underslung on the cross bars rather than sat on top of the roof bars. I hope that makes sense. I intend to do the job sooner than later so if my idea works out I will take plenty of photos and post then for you to consider. My main reason for mounting the solar panel on roof bars is that solar panels sizes are irregular and if the next one fails and I have bracketed it to the roof I could finish up with holes drilled all over the roof where as on roof bars I can easily adjust to accomodate for a different size of panel.

My thinking is my panel will last longer than my van!

 

[Velosaurus]

If the cross bars have a slot in them that will accept 'T' head bolts and if I can invert the cross bars so the slot is underneath rather than on top and they will still fit on the roof rails that way I will intend to invert the cross bars then fit the solar panel brackets to the solar panel then using T head bolts into slot in the inverted cross bars I will mount the panel underslung on the cross bars rather than sat on top of the roof bars.

Yes great idea, I would like mine fitted so the panel is no higher that the side bars. Underslung from the underside of the cross bars is a great idea!

I will take plenty of photos and post then for you to consider.

Yes please!

My main reason for mounting the solar panel on roof bars is that solar panels sizes are irregular and if the next one fails and I have bracketed it to the roof I could finish up with holes drilled all over the roof where as on roof bars I can easily adjust to accomodate for a different size of panel.

Same reason I am looking at it. Also my Skyline poptop has a raised thicker profile on the outer edges which I presume is to add extra strength where the hinge & strut furniture are fitted so its a better place to put the bolts that will hold the weight of a panel and maybe less likely for cracks to propegate from the holes I drill. I have no idea though its just a guess..

My thinking is my panel will last longer than my van!

Quite possibly! It seems solar panel longevity is a bit of a lottery, but I have read fewer reports of rigid ones failing and also good warranty will be a big purchase factor for me. I dont intend to repeat this anytime soon.

 

[DXX]

My thinking is my panel will last longer than my van!

We’ll all have a solar shed in the garden at some point.

 

[Velosaurus]

I am going to Vanstyle in person on Monday(30 mins from me) to look at the cross bars that come with their rails. If the cross bars have a slot in them that will accept 'T' head bolts and if I can invert the cross bars so the slot is underneath rather than on top and they will still fit on the roof rails that way I will intend to invert the cross bars then fit the solar panel brackets to the solar panel then using T head bolts into slot in the inverted cross bars I will mount the panel underslung on the cross bars rather than sat on top of the roof bars. I hope that makes sense. I intend to do the job sooner than later so if my idea works out I will take plenty of photos and post then for you to consider. My main reason for mounting the solar panel on roof bars is that solar panels sizes are irregular and if the next one fails and I have bracketed it to the roof I could finish up with holes drilled all over the roof where as on roof bars I can easily adjust to accomodate for a different size of panel.

Did some more research on this last night. Looks quite straight forward. Seems the Sahara TX3 roof rails are the ones people have used, but more research needed. Good youtube video here. Also T4/5 forum thread here including panel mounting pics, although those pics are a 175w think I would prefer some kind of support in the middle of a 300w panel as well. Just need to test my Skyline roof gas struts will cope with the 35-40kg additional weight towards the rear of the poptop and get the old panel removed ( ) and roof cleaned up.

 

[MattShaw27]

Did some more research on this last night. Looks quite straight forward. Seems the Sahara TX3 roof rails are the ones to use. Good youtube video here. Also T4/5 forum thread here including panel mounting pics, although those pics are a 175w think I would prefer some kind of support in the middle of a 300w panel as well. Just need to test my Skyline roof gas struts will cope with the 35-40kg additional weight towards the rear of the poptop and get the old panel removed ( ) and roof cleaned up.

following this as I intend to do the same.

 

[MattShaw27]

OK, thanks, I'll have to make certain that all fixing points are thoroughly sealed. Thanks for the pointer
CT.

what would be the sealer? thanks

 

[Creamytash]

what would be the sealer? thanks

Not sure what I will use yet.
CT

 

[Creamytash]

I visited Vanstyle today and came away with a pair of Roof Rails in Satin Black to fit a LWB T6.1 and 3 Cross Bars. This is to be fitted to a pop top which requires a bit more work than fitting onto the vans original steel van roof.