Mounting Overland solar flexible 160 Watt panel on yakima tracks

[cbadbox]

Need to get my flexible 160 watt solar panel by Overland Solar mounted to the yakima rack on my Fleet. I was going to use two lengths of 1" x 1" x 1/8 aluminum L channel to span the width of the roof then bolt the panel to the L channel. One person I talked to at Overland Expo West stated thats the set up he used with no additional bracing. I have heard that some recommend additional cross bracing to protect against wind buffeting.

Any input on that type of install? Does anyone have pictures on how they mounted their flexible panel to yakima tracks on a FWC?

Thanks!!

 

[ckent323]

cbadbox,

I mounted the Solar panels to square aluminum tubing then screwed the Al tubing to the square anchor plates that slide in the Yakima track.

http://www.wanderthewest.com/forum/gallery/image/18340-solar-panels-on-fwc-keystone/

http://www.wanderthewest.com/forum/gallery/image/20758-solar-panel-attachment-to-yakima-rack/


You can buy just the anchor plates (double check to be sure you use the correct size anchor plate for your tracks)

https://www.etrailer.com/Accessories-and-Parts/Yakima/Y8810074.html?feed=npn&gclid=EAIaIQobChMI29uDse7G4wIVldlkCh2GyQq7EAQYAiABEgIOpPD_BwE

and in case you need it here is the Go Power Cable entry plate I used (it is under the forward most of the two panels).

I put a rubber grommet in the hole I cut so the cables will not wear through against the thin edge of the Al roof around the hole. I put 3M 4200 under each end and all around the entry plate overlapping the top of the edges. After 2 years no leaks so far!.

http://www.wanderthewest.com/forum/gallery/image/18604-go-pro-solar-cable-entry-plate/

http://www.wanderthewest.com/forum/gallery/image/18605-go-power-solar-cable-roof-gland/

Hope this helps,

Craig

 

[cbadbox]

Craig thank you for your input, great mounting info. I see that your panels were fixed in there own frames. I was hoping someone might have experience mounting a lightweight frameless similar to the OverLand Solar flexible panel might also be able to provide some input. FWC are using those now, I am going to try and contact them this week for their input.

Mario

 

[veryactivelife]

We have 2 of the Overland Solar panels. They were installed by Main Line Overland on frames similar to what the factory is doing. There are several cross supports, 5 I believe. The panels are very flexible and I feel need some type of support. Not only for buffeting, but also for supporting snow load and to prevent water pooling. Unfortunately I do not have any photos of the frames themselves.

 

[cbadbox]

Thank you for the PIC and good input. Talked to FWC Woodland Location today, they will make me one, cost around $140 plus shipping. I don't have access to welding the cross bars, I could pop rivet, yet in the end I would end up spending $60-80 in materials.

 

[cbadbox]

View attachment 35528


Here is the finished install. I purchased the flat and Zee bar from a local supply house, cost was $34 and then purchased some stainless steel hardware to bolt it together. First used good old JB Weld and clamps to put it together. Then drilled for mounting the panel at all the junctions which also makes the mount bomb proof. I was impressed at the strength of the mount with just the JB Weld. Used short pieces of 3M double sided tape in the middle of the cross bars to keep the panel from flapping in the wind.

You do not need the wider 2" flat bar shown on the ends,1" is fine. I had to go with those due to a measurement error.

Also notice I had use rubber washers when mounting on the tracks given that on my install the roof plug for the solar perfectly aligned with one of the cross bars and I did not want to put undue stress on the plug. I would try to avoid that if I was to build it a second time.

Flat bar dimensions .125" (1/8" thickness) X 1.00"

Zee bar demensions 1.00" X 1.125" X 1.125" X .125" (1/8" thickness)

Thanks for everyones input! Next month I will have the camper back on the toyota T-100 and post some pics. The camper is a 2017 fleet shell originally built for a Canyon pickup that I picked up used. I have since removed the bottom filler they but on at the factory to make the fleet fit the canyon so it will fit the T-100 properly.

Mario

 

[Taco around the world]

solar small.jpeg

solar 1 small.jpeg

solar 2 small.jpeg

solar 3 small.jpeg


Here is the finished install. I purchased the flat and Zee bar from a local supply house, cost was $34 and then purchased some stainless steel hardware to bolt it together. First used good old JB Weld and clamps to put it together. Then drilled for mounting the panel at all the junctions which also makes the mount bomb proof. I was impressed at the strength of the mount with just the JB Weld. Used short pieces of 3M double sided tape in the middle of the cross bars to keep the panel from flapping in the wind.

You do not need the wider 2" flat bar shown on the ends,1" is fine. I had to go with those due to a measurement error.

Also notice I had use rubber washers when mounting on the tracks given that on my install the roof plug for the solar perfectly aligned with one of the cross bars and I did not want to put undue stress on the plug. I would try to avoid that if I was to build it a second time.

Flat bar dimensions .125" (1/8" thickness) X 1.00"

Zee bar demensions 1.00" X 1.125" X 1.125" X .125" (1/8" thickness)

Thanks for everyones input! Next month I will have the camper back on the toyota T-100 and post some pics. The camper is a 2017 fleet shell originally built for a Canyon pickup that I picked up used. I have since removed the bottom filler they but on at the factory to make the fleet fit the canyon so it will fit the T-100 properly.

Mario

Cbadbox,
Thank you putting out your design. I recently picked up new Fleet camper and had our camper installer put on 2 semiflexible solar panels on the Yakima tracks and are only supported on the sides. With only 500 miles on the camper the panels have deflected 1/2” already. Needless to say I’m displeased.

So instead of welding the aluminum you just used bolts to hold the cross members to the frame while at the same time using these same bolts to hold the panel in place?

 

[cbadbox]

Taco around the world,

Yes you have that correct, as noted I initially bonded the whole mount with JB weld. Not everyone uses the cross bars, It was suggested by FWC to use them so thats the route I took. I think it would be easy to add cross bars to your setup. Try not to not put to much pressure on your roof when working on it. I read somewhere that using plywood to span the roof while working on it helps.

 

[Taco around the world]

Taco around the world,

Yes you have that correct, as noted I initially bonded the whole mount with JB weld. Not everyone uses the cross bars, It was suggested by FWC to use them so thats the route I took. I think it would be easy to add cross bars to your setup. Try not to not put to much pressure on your roof when working on it. I read somewhere that using plywood to span the roof while working on it helps.

Great thoughts! Thanks. I also like how you used Velcro to keep the PV stable while leveling the brackets. Only wish the professional installer had done this in the first case.