Originally Published on VW T4/T5 Forum in April 2016.
Installing Solar Panels on a VW T5
I liked the way I fitted the panels to Doris the T4 on the rails and decided to do a similar approach, but with some improvements
So … a Pair of 100W panels (I used a my pair of 80W panels for Doris but had the room to go bigger on the T5)
Also wanted a modular approach as well to show how it can be a quick process to add solar to existing conversions and to demonstrate that Solar does not have to stick out.
So using the cross-bars to match the roof rails, some aluminium “L” bar, some Rivnuts and nuts & bolts and I ended up with this bad boy …
The reverse view shows the supports …
Using a combination of ty-wraps and duct tape, got two pairs of cable coming out the back …
And all ready to just drop on the roof …
I chose a more forward postion then you might usually expect. The reason for this is it will would allow additional raised cross bars front and back and so allow load carrying ability still on the roof.
From the side, all pretty stealth …
The cable route is also nice and discrete … (Need to replace the yellow ty-wrap with a clear one though )
The awning rail hides the cables, which is nice, but if the rail was not there, the cables would sit in the guttering anyway and would not be visible.
And then the cables drop down the gap between the D Pillar and the tailgate and will enter the vehicle invisibly.
Coming down the pillar and heading under the cover. I used double-sided numberplate tape to secure the wires coming down. At no time does the gas strut touch the wires so no danger of any wear over time.
Under the bottom cover, I made 5 holes – 4 for the solar and one for the hookup.
And after priming, fitted grommets and then slid the cables through
(It is a little unusual to have two sets of cables for Solar – usually you would have just one pair, a +ve and a -ve, but the controller I used (An Amperor Associates PI25/C) for this installation has a seperate input for each panel. I won’t go into details here, but it allows the controller to do very clever things with the Panels)
Rear Light Cluster refitted and solar all installed without any holes being put into roof anywhere, no gluing or sticking either and a great installation at the end.
Check out the “Solar Panels on Crossbars” Post to see more info on how to fit the panels onto the Crossbars.
If you want to build something similar, there are some links to products at the bottom of this post. These are Amazon Affliate Links, so if you use these you pay no more than going direct to Amazon but we may get a small kickback from Amazon, so we think of it as a little ‘Thanks’ for helping you along.
Alternatively, if you would like us to spec up a setup especially for you and even if you like install it, please drop us a note via our Contact Form
Product Links:
ECO-WORTHY 100W Solar Panel 12V Monocrystalline – https://amzn.to/2Or5fXM
Biard New Solar Cable Extensions 5 Meter Kit With MC4 Connectors – https://amzn.to/2LuGn3z
Selection of RivNuts – https://amzn.to/2LxCuLx
Tools:
Sealey RivNut Tool – https://amzn.to/2K7XJxI