Flexible solar panels on Tundra roof

Added 2x110W solar panels to my roof. Now I'm confident that ice-cream won't melt while I'm backpacking in backcountry

Tight fit, roof actually has a really weird shape (not rectangular), it's not flat, and has 4 strengthening ribs. I tried different configurations, but this one seems to be the easiest to install.

I read that it is more efficient to have an insulating layer between panels and the roof. Initially I wanted to put one large sheet under both panels and mount panels like in this video: https://www.youtube.com/watch?v=PfO6CBNMGd8
However, because of roundness of the roof and ribs, I decided to just go with double-sided tape.

I cut 3 3mm corrugated plastic sheets - between the bars, and 2 thin strips at the edges. Attached them to the roof using 3M Double-sided tape. That flattened the roof a bit. Next, I used the same tape to attach solar panels to both exposed roof bars and plastic sheets.



Eternabond tape sealed the perimeter and area between the panels. And yes, I removed whatever antenna it is on the roof (gps or sirius). Its mounting holes are only covered by tape so I can put it back.

Initially I attached panels to each other using cable ties (between the panels) but it bulged too much under eternabond tape so I removed the ties and sealed the holes with more tape.

Connectors and cables are attached using cable tie mounts (replaced sticky tape with 3M). Both connectors are zip-tied together and then to 3 mounts (which are also covered with eternabond, to protect the roof rather than for durability).



Cables for now are going through rear window. I cut and put some foam into the window gap to reduce wind noise. Later I will either pull them through the one of rubber plugs in the cab, or will drill a hole and use a gland.

In the morning sun I got 21V and 10.3-10.5A (panels are connected in parallel). Now I want to add some current monitors to monitor solar and 2nd battery.

Panels worked great and the installation survived 3000mi trip to Florida already.

Materials used:

Corrugated plastic sheets from home depot: https://www.homedepot.com/p/Coropla...te-Corrugated-Plastic-Sheet-CP4896S/205351385 (48x96 is waaay too much)

3M Double-sided tape: https://www.lowes.com/pd/Scotch-Mount-1-in-x-33-33-ft-Two-Sided-Tape/1002036724 (1 roll 'may' be enough, I wasted couple of feet)

Panels: SunPower 110 Watt Flexible Solar Panel

SunPower 110 Watt Flexible Solar Panel

https://www.amazon.com/SUNPOWER-Portable-Monocrystalline-Lightweight-Connectors/dp/B0779T2SKP/

Connectors: BougeRV Solar Branch Connectors Y Connector in Pair MMF+FFM for Parallel Connection Between Solar Panels

$10 BougeRV Solar Branch Connectors Y Connector for Parallel Connection Between Solar Panels FMM+MFF (1 Pair)

https://www.amazon.com/BougeRV-Connectors-Connector-Parallel-Connection/dp/B07DJ5PHSB

Eternabond tape: EternaBond White Mobile Home RV Rubber Roof Repair 4" x 20' - 20 Foot, 20 Feet

$37 EternaBond White Mobile Home RV Rubber Roof Repair 4" x 20' - 20 Foot, 20 Feet

https://www.amazon.com/EternaBond-WHITE-Mobile-Rubber-Repair/dp/B00AYPCJ9G (20ft was not enough, I was about 3ft short so I bought additional 10ft from walmart)

Cables: Kohree 10 AWG 10 Ft Solar Panel Cable Wire for MC4 Extension Cable, with Female and Male Connector Weatherproof Adapter Kit (10FT Black + 10FT Red)

Kohree 10 AWG Solar Panel Cable Wire 10 Ft Extension Cable, with Weatherproof Female and Male Connector Adapter Kit (10FT Red + 10FT Black)

https://www.amazon.com/Kohree-Extension-Adapter-Connector-Weatherproof/dp/B07WD38KFX

Cable tie mounts: https://www.lowes.com/pd/Utilitech-10-Pack-1-in-Mounting-Base-Cable-Ties/50005764

 

What in particular are you running on this system?

 

Looks great! Have you tried going down the hwy @ 80 mph to make sure they don't fly off?

 

Fridge, all lighting (including camper), all chargers, bug zapper (awesome thing btw).

Was holding just fine at highway speeds for 100miles...

 

Is that an AT Overland shell I see?

 

That is BAD A$$.....
Well done..................

 

Very cool, nicely done OP!

 

What charge controller are you using?

 

Thank you all.

Yes, AT Overland Habitat it is.

Redarc bcdc 1225d + Duracell lead acid 100ah aux battery + Meanwell 400w inverter

 

Interesting. I have solar panels on my RV but I only charge from the panels. Since you’re also driving and have power from the alternator, I can see why the dual source charger would work. I’m usually camped for days and don’t start running the engine until I’m moving, so I use a straight solar charger controller from Victron.

 

a dc-dc mppt controller is awesome. i have the renogy version in my truck. don’t think i’d install a solar system without one.

 

Please show a wide angle pic of the entire truck and set up.

 

X2 please

 

Looks good! I'm in the process of finishing up the 2nd solar install in my truck. I have a sunroof and keep stuff on a roof rack most of the year so I mounted a 100W flexible panel to my tonneau cover. Got a write on up here if anyone is interested ... https://www.tundras.com/threads/solar-system-2-0-build.74696/#post-1908064

 

It's interesting to see how you've tackled the installation, making it work with the unique shape of your roof. The use of double-sided tape and corrugated plastic sheets seems like a practical solution.
Kudos on the attention to detail with Eternabond tape for sealing and cable management. It's clear that your setup is holding up well, even after a 3000-mile trip to Florida.Adding current monitors for your solar panels and the second battery sounds like a great idea to keep everything in check.
But if you ever want to enhance your energy storage for those trips, you might want to check out Battery Storage Solutions at www.acebattery.com for some reliable options.