Fitting a Rigid Solar Panel to a Pop Top Campervan Roof

[@millerzone]

Thanks for the excellent video it was really helpful for when I did my panel. A friend had told me about the thin flexible ones not being good. A few things I did differently which may help someone else. I used the victron 175w panel as I was worried about weight combined with wind pushing the roof down, as the 205 is meant to be 5kg heavier. The 175 is OK and gives about 3 days off grid with a cr50 45w fridge but doing the maths afterwards the 205 should be indefinitely. I put the solar connectors on the outside of the van so I can swap out the panel if I do have problems. I connected the fridge directly to the load output on the victron as this allows you to monitor the draw of the fridge and how often it is turning on and off, which was really helpful in working out if it was getting too hot at the back, but which it was so I fitted some fans to take the hot air away. Thank you again I owe you a beer.

[@highergroundlifestyle]

Thanks for the feedback. Glad the video helped! N

[@rp8540]

Really useful video and nice to see a different take on the usual flexible panels. Appreciate the video.

[@highergroundlifestyle]

Many thanks for the comment. I was worried what the fit would look like but am actually really happy at how it turned out! Cheers. N

[@hansblommers6088]

Super video, thanks. Did you had any problems with the flexible solar panel, mounted directly on a black roof during the hot days last summer? Great tip removing the Sikaflex with the BC-90 cleaner!

[@highergroundlifestyle]

Thank you. Personally, I wouldn’t use a flexible solar panel! They are expensive, less efficient, overheat, need to be glued to your van and don’t last long. Best wishes. N

[@welshieonwheels]

Very useful thank you iv been looking for an alternative to sticking flexible panels , And wanted to know why people didn’t keep the cables inside the pop top . Would it be worth me putting a wind break at the front of the panel ? Very neat thank you and good luck 👍👍👍🏴󠁧󠁢󠁷󠁬󠁳󠁿🇬🇧🇨🇦

[@highergroundlifestyle]

I honestly don’t notice the panels on the roof at all - so a windbreak probably wouldn’t make a difference - but it it may be worth experimenting!

[@angelaandpaul4945]

An amazing video. I feel more confident in fitting my own. My current leisure battery is charged by my van. Can I use in conjunction with the solar panel or should I disconnect the van charging side.

[@highergroundlifestyle]

Glad it helped! The solar panel can be used in conjunction with your existing charger but you’ll need a suitable charge controller as shown in the video. Ours has Bluetooth which connects to an app on the phone and shows battery health and solar charging status. Best wishes. N

[@angelaandpaul4945]

@@highergroundlifestyle thanks I’m going to buy one from the site you recommended 👍

[@highergroundlifestyle]

@angelaandpaul4945 have a chat with them, tell them what you already have and they’ll advise what you need. I’m not on commission - but found their service excellent!

[@spelterworkstiger]

What size, length by width was the panel and what was the power output and where did you get the gland from. I've got to do mine and I'm dreading it as its a brand new van and the pop top is in reverse as its a rear kitchen. Thanks for the info anyway 👍

[@Billybigballs381]

Great tutorial, this video gave me the confidence to install a solar panel on my pop top roof.

[@highergroundlifestyle]

Excellent - well done!

[@deked1728]

Thanks for this. I am wanting to do the same with an older fibreglass poptop but nervous about possible uplift pressure generated at speed, so it was good to see the road test. Did the extra weight make it difficult to raise the poptop - I am wondering if our 13kg panel may require upgrading the springs that offset the weight of the roof.

[@highergroundlifestyle]

Hi, thanks. As noted in the video, we located the panel further back to reduce the impact of weight and place this over the springs. You can’t tell there’s any extra weight and it’s completely unnoticeable when driving or operating. Best wishes. N

[@deked1728]

@@highergroundlifestyle Thanks! Wish me luck..

[@abr00ky]

Fabulous guide. I'm doing the same with the same panel. What bolts/nuts did you use to attach the panel to the van? My renology panel brackets can use self tapping screws but they'll be no good

[@highergroundlifestyle]

I used stainless bolts - the smallest size I could get away with. The length required can vary depending on the thickness of the roof material but always ensure at least two threads are showing past the nut. Good luck. N

[@abr00ky]

@@highergroundlifestyle thank you. I came to a similar conclusion but with some sealing washers on the top. 👍🏻 Great video. Thank you.

[@highergroundlifestyle]

No worries. Cheers. N

[@bernardmiler3106]

​@@highergroundlifestylewhen you mention attaching the panel to the fibre glass pop top roof, am I correct in understanding that you used stainless nuts and bolts? Self tappers would be the easiest but I don't like the idea of them holding down the panel over time without stripping the fibre glass itself. I am at a bit of a loss as to how you can use nuts and bolts with out penetrating the roof liner material inside the van? Cheers.

[@angelaandpaul4945]

Hi. What size bolts did you use to fix the aluminium brackets to the pop top roof. (Video is awesome some great tips thank you)

[@highergroundlifestyle]

I used the shortest stainless bolts I could get away with - just enough to get a nylon nut on so they could be covered with soft covers. The size depends on the thickness of the material it needs to go through then and may differ on different parts of the roof. Cheers. N

[@angelaandpaul4945]

👍

[@angelaandpaul4945]

Hi my camper currently has the leisure battery charged by the van itself. Can I use a solar panel in conjunction with my current system, or do I need to disconnect the van charging side? Thanks

[@highergroundlifestyle]

You most certainly can but you will need a charge controller to do this. It will allow your battery to be charged by both the van’s alternator and your solar panel, ensuring that you always have a means to recharge your battery whether you’re driving or not! That’s what I have installed here.

[@angelaandpaul4945]

@@highergroundlifestyle thanks what does that look like

[@angelaandpaul4945]

Do you mean what is sullied in a full kit

[@highergroundlifestyle]

@@angelaandpaul4945 In this video it is the blue box shown at 15minutes 20 seconds.

[@veddyveng]

Great vidoe, how do you find the weight of the pabel effecting the pop top lift rams with the added weight?

[@highergroundlifestyle]

Hi, many thanks, it doesn’t have any impact as the weight is all to the rear. This was part of my planning considerations. Cheers. N

[@veddyveng]

@highergroundlifestyle just installed a 400watt domestic panel weighing around 20kilo, the only difference I feel is it's slightly harder to push up. Had some 30mph gusts the other day and didn't budge

[@highergroundlifestyle]

Well done!

[@davidsharp6477]

Hi - really good video - I am looking at doing the same thing. My pop top is ridged like yours. It has a slight concave curve in the lower section - presume yours has the same - how did the fittings and rigid panel cope with the flex / bend ? Does the solar panel have any flex in it ? Thanks

[@highergroundlifestyle]

David, many thanks. Yes, I recognise your comments re the concave roof! The panel does has a slight bend in use and the frame has taken this up although it is not obvious. The flatness of the panel/frame also sits comfortably within the overall shape of the roof and actually looks really good. I’m glad I went for a rigid panel and one that was this size. It looks “right” on the roof, has no trailing cables/obvious glands and works really well. We’re just back from a week away - most of which was off grid and never had issues with battery capacity. Ice cream and lollies were also still frozen hard when we got back! Best wishes. N

[@davidsharp6477]

@@highergroundlifestyle thank you - appreciate the feedback

[@lhann11]

Hi do I need any special drill bit for the holes in the roof?

[@highergroundlifestyle]

No, but it’s steel so HSS probably best?

[@sandraP7742]

Hi, will I still be able to get under any drive through barriers.....eg Costa

[@highergroundlifestyle]

A pop top roof probably stops you getting through most barriers - a rigid solar panel on your roof would certainly prevent this. Of course it all depends on the barrier! Cheers. N

[@stevenwhitehead208]

Could you please add a link to the brackets. The only ones I can find comes with screws and not nuts and bolts. Thanks.

[@abr00ky]

Same for me. Did you do this and what nuts and bolts did you use?

[@stevenwhitehead208]

I used stainless steel nuts and bolts and nylon washers so not to get severe corrosion from the stainless steel onto aluminium

[@abr00ky]

@@stevenwhitehead208 thank you. I've taken the same route. I'm going to have to saw off the bolts on the inside so picked up some M6 black dome bolt nut caps to make it look tidier on the inside and to protect heads a bit more.