Mounting a solar panel on the rear shell.

dspiveysr

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Middle Ga
I have a Renogy 200W ShadowFlux panel that I plan on mounting on the rear shell. Panel is ~ 49" x 30" and 24lbs
Does anyone have any experience with using 3M VHB tape for mounting panels ? I would rather not use screws making roof penetrations.

David
 
David, VHB tape works great for flexible panels, and it is pretty good for panels mounted front-to-back on the larger "front" shell. But on the rear shell, you probably have to mount that panel side-to-side. The outside of the rear shell has a lot of curvature, both from the center ridge (towards street and curb sides) and from the higher "seal" in the middle going down towards the rear. Those curves make it difficult for panel mount Z-bars to make good contact.

The "flat bottoms" of those Z brackets are typically about 4 inches long, one inch across. You can bend the one-inch side pretty easily, creating an angle different than 90 degrees, but bending the longer length is nearly impossible. You can't match the curvature of the shell roof, and the gaps create a problem in trying to use VHB tape.

I have a solid-framed glass panel back there, it's very similar to yours. I built a curve into bracket bottoms by using VHB tape segments of of different thickness. After pushing the panel and brackets down into the rear shell roof, I also applied 3M boat sealant around the bracket edges to further strengthen and weather-proof those attachements.

But that took too much time, and it is weak. A far better scheme would be to use 2 bolts on each Z bracket. On the outside, after drilling holes for the bolts, fill the holes with boat sealant before tightening the bolt through the roof. The inside ceiling should have a big "fender" washer above the nut, you might add another washer outside too. When you push the bolt into the hole and begin tightening against the nut and washer inside, boat sealant will fill into the bolt threads and also leak out under the washers - making a great seal, very strong and waterproof. Just wipe away any excess. I would use SS bolts and washers, because aluminum is too weak.
 
David and Rick, I've always been told to avoid using stainless and aluminum together. Something called galvanic corrosion can happen. Use a rubber washer between the two.
 
Rick,
Not sure I can talk the wife into "big" fender washers on the ceiling above the bed.
I may try some aluminum flat stock on the curved roof section to see if i can bend it to match the curve and mount the brackets to the flat stock countersinking the heads into the stock.
Your opinion on that option ?

Thanks
David
 
I have a Renogy 200W ShadowFlux panel that I plan on mounting on the rear shell. Panel is ~ 49" x 30" and 24lbs
Does anyone have any experience with using 3M VHB tape for mounting panels ? I would rather not use screws making roof penetrations.

David
I have used 3M VHB tape on 4 different TrailManors. a Coleman pop-up with aluminum roof, 3, Class A motorhomes (fiberglass roofs) and 2, cargo trailers. Never had an issue. The 1st pic is my last TM 2720SL. The 2nd pic is a close friend's Class A. He's been back and forth across country several times and encountered winds of 70mph. No issues with the VHB tape.

Having said all that, here is how to use the VHB tape. Mount the Z-brackets to the solar panel by screwing through the side frame. Pre-drill the little ears (slightly larger than the screw) and use S/S self-taping screws into the frame. (zoom in on my pic).

Lay the solar panel on the roof and slightly bend the brackets to lay flat (as Rick29 mentioned above). No tools required. Remove the panel.

Clean the roof with a mild degreaser (like Simple Green or Citrus cleaner). Rinse and dry well then lightly wipe the attaching areas with rubbing alcohol (including the Z- brackets). Put the 1"x4" strips of VHB tape on the brackets and remove the tape backing. Set the panel down exactly where you want it (you only get 1 chance).

Here's the important part........ press down on the top side of the flat bracket as hard as you can for 30-seconds each (just do 1 at a time, no hurry). I use a 12" long piece of 2x4 with the cut end pressing on the bracket. This causes a chemical reaction that activates the adhesive. Leave it set for 3-days. It ain't goin' anywhere.

If you ever want to remove the brackets. Just slide a razor blade under the Z-bracket and slice through the tape. It'll come apart and then rub the residue with your thumb and it'll roll up in a ball and you'll have a clean surface.
 

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David and Rick, I've always been told to avoid using stainless and aluminum together. Something called galvanic corrosion can happen. Use a rubber washer between the two.
Regular steel and aluminum has a lot of that effect, but stainless is more immune.
Rick,
Not sure I can talk the wife into "big" fender washers on the ceiling above the bed.
I may try some aluminum flat stock on the curved roof section to see if i can bend it to match the curve and mount the brackets to the flat stock countersinking the heads into the stock.
Your opinion on that option ?

Thanks
David
SS fender washer can be painted to match the ceiling, I think that larger aluminum plates would be more distracting to view.

- - -
Each of the panels in Wavery's 2720 pair is oriented front-to-back, avoiding most of the 'bracket angle problems' which you will have in mounting a much longer 200W panel street side to curb side. I used only VHB on my rear-shell 200 watt glass panel, but it was difficult to make the curves using tape alone. (That panel hasn't shifted in high-speed travel travel or other high winds, but I could probably rip it loose with only my bare hands).
 
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I mounted a 400W panel on the rear shell but elected to drill and seal so that there was a mechanical connection rather than tape. I have had VHB tape fail, probably due to incomplete or incorrect prep, but as this was on the factory side of the piece that I mounted, window rain guards, I am leery of a tape only connection. I only sealed to outed penetration so that if the sealant failed at some future time I would see the leak on the inside on the bed. I figure that this is better than water being trapped between the aluminum shell layers.
 
I mounted two panels on the rear using Z-brackets and 1” VHB without penetrations as Wavery has done. His instructions are sound. I would add that you must use quality VHB and inspect annually. PM if you’d like more details
 

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