Renogy 200W Flexi-Panel Install

[ginkster]

I’ve got a 200W Renogy flexy PV panel that I’ll be fitting after I’ve finished installing a DC-DC charger and battery maintainer, so am interested to see how others are installing them.

My plan is to use a 10mm polycarbonate twinwall sheet between the PV panel and the roof. The PV panel will be attached to the twinwall with Sikaflex 522, and the twinwall will be stuck to the roof with 3M VHB tape. This will provide an air gap to keep the temperature of the PV panel at a reasonable level. As a safety precaution, the PV panel will be attached to the roof bars with two cords fastened to each of the PV panel’s front mounting eyes. According to my measurements, this arrangement should not increase the actual clearance height of my van’s roof by more than 5mm.

I liked at polycarbonate sheets but decided against in the end, partly because I was ending up with 2 interfaces to stick down and the marginal height increase (I’m very close to 2m!).

I put down a sheet of PPF and the keyed the surfaces with a scotch pad before using Sika 552 to stick the panel down. I applied a 8-10mm triangular bead (instructions on Sika website) to give a 4-5mm deep bead once the panel was applied. I also used a few rubber spacers to ensure the panel didn’t get pushed down too far - I wouldn’t bother next time. The beads are full width at the front then the rest run across the panel but have a 10-15cm gap in the middle to aid airflow and to allow any water to escape. They are placed at about 15cm apart to fall in the gaps between individual cells. The front edge is smoothed so there is no edge to lift in the airflow. It’s survived all weathers and high speeds no problem at all and is in the same state it was when fitted.

 

[Captain Quick]

I’m fortunate that the SCA roof on my van has two raised flanges at the edges of the roof both sides. The PV panel and twinwall ‘sandwich’ will be fitted in between these. The combined thickness will be around 10mm and even with the slight raised central area of the roof, the top surface of the PV panel should be just a couple of millimetres proud of the tops of the flanges. As the overall height should be unchanged, I’m trusting I won’t have an issue.

 

[peteaufc]

I’ve got the same 200w panel and it’s been great for the year I’ve had it. I’ve seen just over 200w in summer sun. Attached to the poptop with Sikaflex on a piece of PPF just in case it ever needs replacing. I’ve ensured there is a 4-5mm gap below it to give a degree of airflow.

View attachment 283613

@ginkster looks like you used clear PPF and that has held up well - are you able to share the make/manufacturer of the PPF you used?

I got a 200w Renogy panel last summer, but didn't get a chance to fit before we went away, so it's still sitting there to be done!

 

[Stay Frosty]

@Stay Frosty I am struggling to understand why you are having a constant battle to keep your panels from unsticking themselves, when every other post (that is about adhesion) is about the difficulty of getting them off and so people are using vinyl or PPF for this reason. Can you think of a reason?

I reckon the flour I used should have been organic?
Like a few victims on here my fibreglass pop top is at an age (6 yrs) where the gelcoat keeps oxidising and effectively sheds leaving the surface slightly chalky, while this can be cut back and repolished anything stuck to that exfoliating layer can't hold on to the dust.
In all fairness I haven't actually lost a panel thanks to a fellow motorist indicating that my roof mounted airbrake had deployed but realistically if he hadn't pointed out our problem it would have snapped completely when we jumped to warp speed.
I'm not looking forward to the panels failing in time but I reckon a well aimed fart will probably detach them at that time so not all doom.

 

[ginkster]

@ginkster looks like you used clear PPF and that has held up well - are you able to share the make/manufacturer of the PPF you used?

I got a 200w Renogy panel last summer, but didn't get a chance to fit before we went away, so it's still sitting there to be done!

It was the one below off eBay, but it doesn’t seem to be available anymore. Not sure if the make of PPF as it wasn’t printed on the backing. I paid £25 for a 2 x 1.52m roll.

 

[peteaufc]

Thanks, take it there haven't been any issues with good adhesion to the glossy PPF/wrap over time, so might be the way for me to go. Although it's on the roof, I'd still rather avoid a wrap that is too different to the paint or solar panel surround.

 

[ginkster]

Thanks, take it there haven't been any issues with good adhesion to the glossy PPF/wrap over time, so might be the way for me to go. Although it's on the roof, I'd still rather avoid a wrap that is too different to the paint or solar panel surround.

No issues at all. I lightly keyed the surface of the PPF and the panel with some Scotchbrite (green scouring pad)and then cleaned with isopropyl before applying the Sika. You can see the keyed areas on the PPF on the pic in the previous post.

 

[tommy_t6.1]

No issues at all. I lightly keyed the surface of the PPF and the panel with some Scotchbrite (green scouring pad)and then cleaned with isopropyl before applying the Sika. You can see the keyed areas on the PPF on the pic in the previous post.

I dismissed solar for a while, mainly as we never had power in the van. Now we do, I can 100% see the benefits of it!

The PPF is a genius move as i don't want to permanently glue/screw anything to the actual poptop! Will definitely be following suit!

 

[JumpShip]

I dismissed solar for a while, mainly as we never had power in the van. Now we do, I can 100% see the benefits of it!

Exactly the same as us and the idea of harvesting 'free' power seems a complete no brainer now .

 

[peteaufc]

¹

It was the one below off eBay, but it doesn’t seem to be available anymore. Not sure if the make of PPF as it wasn’t printed on the backing. I paid £25 for a 2 x 1.52m roll.

I've had a look on ebay, but not seeing any PPF at a similar price for that size of roll/sheet. Everything seems to be £80+ for that size. Does anyone else have other recommendations of what they used?

 

[Skyliner33]

I reckon the flour I used should have been organic?
Like a few victims on here my fibreglass pop top is at an age (6 yrs) where the gelcoat keeps oxidising and effectively sheds leaving the surface slightly chalky, while this can be cut back and repolished anything stuck to that exfoliating layer can't hold on to the dust.
In all fairness I haven't actually lost a panel thanks to a fellow motorist indicating that my roof mounted airbrake had deployed but realistically if he hadn't pointed out our problem it would have snapped completely when we jumped to warp speed.
I'm not looking forward to the panels failing in time but I reckon a well aimed fart will probably detach them at that time so not all doom.

Oh thats not great. I had the fibreglass pop top painted. Im guessing I wont have this issue down the line.

Couldn't you get your roof painted to stop the issue? Or maybe a full roof wrap? I suppose a mechanical fixing might be a solution?

 

[Stay Frosty]

I think with paint over fibreglass it obviously can be done as in the case of new fibreglass or composite bodied cars but retrospectively is a bit more of a gamble, think back to the early noughties and Max Power style modded cars with peeling bumpers, spoilers and crazed fibreglass.
Along with being torn over 20" wheels or not, getting the pop top sprayed body colour has been on my mind too however chestnut brown can be a pretty dark colour at times with the visible gloss black sides of the roof not clashing too badly so it's cut and polish again... bit like a trip to the barber these days.

 

[Skyliner33]

I think with paint over fibreglass it obviously can be done as in the case of new fibreglass or composite bodied cars but retrospectively is a bit more of a gamble, think back to the early noughties and Max Power style modded cars with peeling bumpers, spoilers and crazed fibreglass.
Along with being torn over 20" wheels or not, getting the pop top sprayed body colour has been on my mind too however chestnut brown can be a pretty dark colour at times with the visible gloss black sides of the roof not clashing too badly so it's cut and polish again... bit like a trip to the barber these days.

Its been years since I've needed a trip to the barbers.

 

[Drive Wayne]

Its been years since I've needed a trip to the barbers.

I enjoy a trip to my local Turkish Golden Scissors/front for crime syndicate whatever. 1.5 all over and the wax on a stick up your nose and ears to remove the fastest growing hair I have! £9 every few weeks, come out smelling of cheap cologne, lovely!

 

[Skyliner33]

I enjoy a trip to my local Turkish Golden Scissors/front for crime syndicate whatever. 1.5 all over and the wax on a stick up your nose and ears to remove the fastest growing hair I have! £9 every few weeks, come out smelling of cheap cologne, lovely!

That makes it sound a bonus not to need it (except the wax on a stick)