Chevy Astro DIY Stealth Camper Van Build EP 6: Solar Panel Installation & Lithium Battery

Custom no-drill soalr panel mounting system on my stealth camper van build. VHB adhesive tape and sheet metal mounting bracket system for 2 100W Renogy solar panels + mounting a 100ah lithium battery in my Chevy Astro stealth camper van build. I used aluminum tubing for the frame and made my own brackets to mount my solar panels to the roof using VHB adhesive tape. It works!
Mounting solar panels on an RV camper with a flat roof is easy, but to mount solar panels on the roof of a van like a Chevy Astro, with a curved roof, is much harder. Regular solar panel mounts may not fit the curvature of your van's roof. Additionally, if you want to mount your solar panels without drilling through the van's roof, there are fewer options. Most of the no-drill or drill-less solar panel mounting brackets out there are meant for flat roofs. So, I came up with my own no-drill solar panel mounting solution for curved van roofs.
AMAZING 6 week DIY stealth camper van build! In this 10-part van build series, I'll be converting a Chevy Astro Van into the budget friendly campervan of my dreams. I'm calling it the Adventure Van, because that's what this van will allow me to do; become a full-time outdoor adventurer and nomad!
Visit my website for a written description of my Chevy Astro Stealth Camper Van Build project:
seekinglost.com/van-life/stealth-camper-van-build/lithium-battery/
seekinglost.com/van-life/stealth-camper-van-build/solar-panel-installation/
**LINKS TO TOOLS & MATERIALS USED IN THIS VIDEO**
Materials:
Solar Panels (100w) - amzn.to/3ReWikz
100a Lithium Battery - amzn.to/3xhLuub
Renogy 12V 50A DC-DC MPPT Charger - amzn.to/3CWKvmK
Solar Panel Wires Roof Entry Port - amzn.to/3e9Qkmf
Renogy 20FT 10AWG Solar Extension Cables - amzn.to/3wSWbTq
Solar Panel Y Branch Connectors - amzn.to/3qa4Ddi
Spax Construction Screws - amzn.to/3RvNJ4o
Ratchet Straps w/ Carabiners - amzn.to/3q9dyvC
Aluminum Tubing & Connectors - eztube.com/
Sheet Metal Screws - amzn.to/3RgTHXl
Rivet Nut Set - amzn.to/3TA3LfH
Hinges - amzn.to/3BbL1f8
16 Guage Sheet Metal Plate - amzn.to/3eoCjBe
Loctite Threadlocker 242 - amzn.to/3QfjVZ2
Angle Aluminum - amzn.to/3eqdPI4
3M VHB Tape - amzn.to/3ARwfJ1
Heavy Duty Waterproof Rubberized Roof Tape - amzn.to/3BdXT4p
Loctite PL Max Contraction Adhesive - amzn.to/3Kwdtvt
Sikaflex 715 - amzn.to/3CIltHG
Tools:
Rivet Nut Tool - amzn.to/3QaoYtv
Dewalt Cordless Impact Driver - amzn.to/3cRg46B
1/4" Drive Quick Release Bit Extension - amzn.to/3Qh2UO6
Center Punch Set - amzn.to/3wVgBeC
Craftsman 3/8 Drive Drill - amzn.to/3KKAwCK
Craftsman Socket Set - amzn.to/3cIKBUa
Dewalt Compound Miter Saw - amzn.to/3BdDJrc
Jigsaw - amzn.to/3elVQ5A
Dewalt Angle Grinder - amzn.to/3TBJNkN
File Set - amzn.to/3THj85P
C Clamps - amzn.to/3L1pSYF
Countersink Bit Set - amzn.to/3Rs6K82
Seeking Lost may earn an affiliate commission if you purchase something through the links above.
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[@jeffwrinkle575]

Really enjoying this series. Making mental notes as I watch to use your methods in a future van build of my own. One suggestion is the front mounts for the solar panels, with two different types of metal, aluminum and steel I would watch for corrosion over time due to the di-electric difference between the two metals. Wouldn't hurt to place some time of nylon or silicone layer between the steel and aluminum.

[@vutEwa]

nice job Eric!

[@SeekingLost]

Thank you!

[@jerrylim2282]

Should place a plastic tray underneath the battery in case any acid leak.

[@Twobarpsi]

Excellent craftsmanship!! Great design you came up with as well 👍

[@SeekingLost]

Thanks! It was really cool to see this design work out, it's something I came up with on theory and it was surprising how well it worked. Probably for the best considering the consequences if it hadn't worked!

[@waymanbell]

Good job on the solar install. I look forward to seeing videos of your travels and hike when you have the van completed. I am looking for a good used truck camper I can use to get out and do some traveling myself and might need to install solar if the one I get doesn't have it.

[@PhenomenalWorld]

Very excellent presentation and nice job! Considering the same for my Astro. Have you noticed any decrease in mpg due to either weight and/or wind-resistance?

[@tzec-6359]

This was a great build. I am interested if this system could work for commercial use (auto detailing) if not how could i tell how many panels/batteries I would need?

[@gregoryc.8348]

❤😂love your style i hehe the same van is there a way you can show me how to do my van as yours??

[@SeekingLost]

Thanks Gregory! Well this is a 10 part series that details the van build, give that a watch. Also, if you check the video description, there's links to my site with written instructions and photos. Also have a full parts/materials list there. And if all else fails, shoot me an email and I'll try to help you out with any specific questions you have. Good luck with your build!

[@sakocat]

How well is your battery working. Im just starting a build and am using the same solar panels

[@SeekingLost]

Battery and solar panels are working excellent. 200w of solar is the perfect pair with the 100ah battery. Here in the Arizona desert, I can recharge 65%+ of my battery in one day (more in the summer, this is the winter/spring months), and that's way more than I would use in a day.

[@sakocat]

@@SeekingLost thank you

[@dhanso928]

I must say that everyone I've encountered with lithium battery installations, people who actually camp, wish they had not gone that route. We have spent 3 - 5 months off the grid for 20 yrs and find normal batteries are just fine. We recently "upgraded" to a 2006 four wheel popup truck camper, it has the original golf cart 2 6v batteries. Despite it being the wet stormy winter in the southwest we never once got below "good" on the old time charge meter with one 75w solar panel flat on the roof and one portable, all through a renology charge manager. AND.. even. well below freezing they always take a charge and they supply power. Never had to use the truck to charge anything. Inexpensive, durable, dependable. You can keep the lithium. An aside: To refill our water tanks without moving our camp we brought 6 gal jugs and transfered the water with a drill-powered little hose. Many mornings the lithium battery drill would not work till we heated it up. We kept that charged with a lighter plug cheapo invertor, running off those old school and pretty old normal batteries. I know lithium is the Gucci thing...but it has it's issues, for sure.

[@SeekingLost]

I love lithium! Why would i want two batteries that can only be discharged to 50%, when i can have one? Only had one morning ever in 2 years in this van where my batts wouldn't charge, for about an hour, until it warmed up. Can still use the battery in the mean time. No biggie. I hate cold weather and almost never camp in places that get below freezing. Your van keep your two batteries, I'll stick with lithium.

[@dhanso928]

@@SeekingLost If you are always in warm weather then other than cost there's no drawback to lithium batteries. They are lighter, and they do pack more power, for sure.

[@Auxbeam]

Hi Do you need some great lighting for your car for better driving, off-road? We're the pro auto lighting manufacturer for nearly 20 year and we're looking for sponsorship!

[@wowyummyyy]

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