Low Profile Solar Installation

 

Profile of Solar Panel

Here's a few details about the installation of a 200W semi-rigid solar panel.  This is mounted on T-Track and polycarbonate.  Using aluminum T-Track allows the sliding of bolts onto the track.  These are in-turn used to fasten the panel.

End view of T-Track

I cut the T-Track to the length of the panel and fastened with bolts.  VHB tape was then applied to the track. 

VHB applied to the right track, which is bolted to the solar panel

 After cleaning the fiberglass roof of the Roadtrek with soapy water and alcohol I lifted the assembly to the roof.  The panel was positioned, then the film removed from the VHB tape.  I applied pressure to get a good seal.  I then unbolted the solar panel, and using a rubber mallet I lightly hammered the entire length of the T-Tracks.

I also installed pieces of Eterna-bond tape, overlapping the T-Track.  This is a backup for the VHB tape.

I installed a 24 inch x 48 inch polycarbonate ventilated sheet between the T-Tracks.  This provides a center support for the solar panel.  It is about 1/4 inch thick. 

I then applied sections of polycarbonate panel atop the T-Tracks.  This will further suspend the solar panel above the roof and provide for some ventilation.  Slots were cut in the sheets at the location of the bolts.  Eight sets of bolts, washers, lock washers and nuts fasten the solar panel to the T-Track. I may eliminate the "crush" at the bolts by installing shims.

Side view of solar panel mounting

Here's a view of the Eternabond mounting approach. This was taken prior to dropping the panel onto the T-Track and aligning the bolts. I used Eternabond white, 2 inch.  This is UV resistant:

As can be seen in the photo at the beginning of this post, the panel and mounting is barely visible.  I'm going to give it a few months to "age" in the sun and see how the mounting does, before taking a long trek.

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Note: No AI tools were used to produce this blog. Most photos are unretouched.

(c) 2025 N. Retzke