Tomthumb62
Solar Wizard
- Joined
- Sep 25, 2022
- Messages
- 1,871
Learn from our mistake!
We just spent the last two months doing a major remodel on our custom made camp trailer, which included replacing about 90% of the solar system. The last two days were particularly rushed, little sleep and this led to a big mistake because I wasn’t thinking clearly.
On the first road trip out (less than 24 hours after install) one of the flexible panels tore from the roof, leaving only 1 out of the 6 bolts still attached. The panel seems to have survived but time will tell.
The fatal mistake was we used washers that were far too thin between the bolts and the panel. The panels’ metal grommets stretched and tore as did the thin washers. I’m pretty sure that had we used thicker washers this never would’ve happened. The plastic sheeting under the panel for airflow/cooling may have contributed to the problem, but since we lost it, I can’t know for sure.
What also used a new installation method than previously (we reinstalled the original two flexible panels without the plastic insert sheet and with wood screws, solid washers, all stainless steel). We modified the method described by this video:
However, we didn’t use the metal t rails he used, but instead used thick metal plates with 1/4-20 bolt holes T-nuts. The t-nuts went up through holes in the plastic sheet, then through the grommet holes, washers and bolted down with stainless steel 1/4-20 bolts. A strip of Gorilla tape across the front edge of the panel +plastic was installed to reduce lifting during driving (this worked well for over 9000 miles on our original panels that didn’t have the plastic sheet underneath. )
The fix will be much larger washers and lock washers and more Gorilla tape. And glue or industrial Velcro between the plastic sheet and solar panel.
We mounted two panels in this method but only one failed like this. The other one is fine.
We just spent the last two months doing a major remodel on our custom made camp trailer, which included replacing about 90% of the solar system. The last two days were particularly rushed, little sleep and this led to a big mistake because I wasn’t thinking clearly.
On the first road trip out (less than 24 hours after install) one of the flexible panels tore from the roof, leaving only 1 out of the 6 bolts still attached. The panel seems to have survived but time will tell.
The fatal mistake was we used washers that were far too thin between the bolts and the panel. The panels’ metal grommets stretched and tore as did the thin washers. I’m pretty sure that had we used thicker washers this never would’ve happened. The plastic sheeting under the panel for airflow/cooling may have contributed to the problem, but since we lost it, I can’t know for sure.
What also used a new installation method than previously (we reinstalled the original two flexible panels without the plastic insert sheet and with wood screws, solid washers, all stainless steel). We modified the method described by this video:
However, we didn’t use the metal t rails he used, but instead used thick metal plates with 1/4-20 bolt holes T-nuts. The t-nuts went up through holes in the plastic sheet, then through the grommet holes, washers and bolted down with stainless steel 1/4-20 bolts. A strip of Gorilla tape across the front edge of the panel +plastic was installed to reduce lifting during driving (this worked well for over 9000 miles on our original panels that didn’t have the plastic sheet underneath. )
The fix will be much larger washers and lock washers and more Gorilla tape. And glue or industrial Velcro between the plastic sheet and solar panel.
We mounted two panels in this method but only one failed like this. The other one is fine.
