James Cook Forum

Hi all!

I'm about to order solar panels for my 2004 JC with the large Heki. Unfortunately I'm disabled for another month since I fell of the ladder while measuring the available area on the roof. Crushed my right foot and now it's plastered and put together with eight screws and three plates

I've measured the available area behind the Heki to be around 125*90 cm. Has anyone measured the available area in front of the Heki for a flexible solar panel? I would be very grateful if anyone has done this and can share the figures so I can order the panels and mount them when I'm no longer disabled.

Best regards,
Jan

1. The front part of the fiberglass top is concave rounded in two directions. Depending on how you install the semi-flexible panels, you may have an inch or so variation in dimensions. Like installing a solar panel on a large ball.

In 2013, I had two Solbian 100 watt panels installed using 3M Dual Lock (like plastic Velcro) on the perimeters with Lexel caulk at the very front edges.

BUT, to keep the two panels touching down the centerline of the Westy, the installer sliced off a portion of one of the Solbian panel border so the long edges of the two panels would touch in the middle.

Also, cut off an outside corner of each panel at the very front.

The current Solbian 100 watt panel is 43.66 inches long and 21.50 inches wide. Double-check if that is the same size back in 2013.

2. As you have a Heki skylight, you probably have the front spoiler which takes up some space.

Also, the black plastic caps for the inserts for kayak carrier could be removed and covered over to gain a sliver of space.

3. If you want to keep from slicing the edge off a long edge of a panel and the outside corners, you could use polycarbonate backing with bolts to create a flatter surface.

https://sprinter-source.com/forum/showp ... stcount=11

https://sprinter-source.com/forum/showt ... ight=Solar

Please post.whatever you do. Thanks.

Also, you can gain some roof space by getting rid of little vents (James Cooks may not have as many as NAFTA version). This owner fiberglassed the top holes and added a kitchen exhaust vent on the side.

https://sprinter-source.com/forum/showt ... hp?t=54496

There are two (2) King Solar semiflexible panels (each 46.1" x 21.4") so a little more usable width if get rid of little vents.

OldWest, thank you very much. It's true that we have the integrated spoiler in front of the Heki. I've previously measured the area behind the Heki and noted 125cm*90cm as available space. The mushroom vent is mounted above the kitchen.

It was when I measured the area in front of the Heki that I fell

The panel I've been looking at is this: https://www.jws-solar.de/flexibles-sola ... _1076_1328
I was hoping that I could mount two of them, one in front of the Heki and one behind. I've already purchased a Victron SmartSolar 100/20 regulator that will work nice together with my Victron Smart Battery monitor.

The website seems to say that the 120 watt solar panel is 1060mm x 800mm (41.7 inches x 31.5 inches or so) so they should easily fit. It's good to use matching identical panels. So you'd have a total of 240 watts.

To keep the semiflexible panels cooler, you may want to use double-walled polycarbonate panels cut to size underneath, especially on the flat roof one. That would provide air circulation.

I think a key point is easy removal as these panels do not last forever and replacement may be needed in the future.

For the flat roof behind the Heki, you could design mounts which allowed you to remove the panel and use as a portable. Try to make sure that the kitchen mushroom vent does not cast even a small shadow onto the panel.

For the curved front roof, you may want to consider a method of mounting which allows for the dual curvatures.

For example, gluing the panel directly to the roof does not work because it's like gluing a large credit card onto a ball--you get puckering on the edges.

Alternatives include: 3M Dual Lock allows for variation on the perimeter. Polycarbonate panel and mechanical fasteners flattens the mounting surface.

Hi, maybe that Foto helps a little bit




Best Whishes

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Thanks for the picture and hints. Our roof has the same layout except no tv/sat antenna.

I must admit that I have not thought of the dual curvature of the roof in front of the Heki. Do you think that 3M Dual Lock will keep the panel securely fastened in this (for speed wind) very exposed position? I believe that if I mount it flat at the front end there will be (a considerable?) part of the sides that will be impossible to mount flat to the roof. Would double-walled polycarbonate help in flattening out the curvature?

I had a look at double-walled polycarbonate - perhaps something like this? https://www.hobbyvaxthus.se/p/kanalplas ... gKfBfD_BwE
I'll certainly use something like that on the flat area behind the Heki, glued against the roof and then attach the panel to it with 3M Dual Lock.

1. 3M Dual Lock will be fine to hold down a lightweight, semiflexible solar panel.

A. There are different types. Check the links to see which one BruceSchwab and Solbian used. Have two solar panels on front since 2013 without any issue.
B. They have a thickness so you will need to add several strips in the middle of solar panel (between each row of solar cells) or something else so the middle of solar panel does not dip.
C. Because of the mushroom hooks, the 3M Dual Lock allows curvature of the solar panels without puckering.
D. Polycarbonate in the front curved area will provide cooling but also a lot of.thickness. The link showing the polycarbonate on the curved front showed mechanical fasteners. I think it looks better without the polycarbonate on the curved, more visible portion.
You can test fit a piece of polycarbonate to see how it fits on the curved portion as well as the solar panel alone.
E. Adding a Lexel or other caulking along the very front edge of solar panel in front prevents any wind going through mushroom fasteners. Prevents any uplift.
F. Add a small weephole through the caulk and the 3M Dual Lock to allow any moisure to weep out the front.

2. Scaffolding

A. Use two.sets of.scaffolding, one on each side. You can also add a wide wood plank across the hood supported by the scaffolding to reach the front of solar panel.
B. Remove the dome of Heki skylight (screws on hinges and brackets on arms). Can stand on top bed to work on solar panels.
C. Ramps. May want to put front end on ramps with wheel chocks. That makes the front roof more level for installation.

3. Polycarbonate

For flat roof, you can use the 3M Dual Lock to hold the polycarbonate to roof. Alternatively, there are nice plastic corner and side brackets which could also be used. These brackets can be screwed or glued to roof.

You can use 3M dual sided tape to hold the solar panel to the polycarbonate. The dual sided tape is thinner and permanent.

4. Check these links.

Brsides the links I mentioned before, check these links as well.

https://oceanplanetenergy.com/

https://oceanplanetenergy.com/solar-pow ... cessories/

https://www.bruceschwab.com/wp-content/ ... adius1.pdf

Above pdf recommends 3M Dual Lock 3560 version:

"When using Dual-Lock tape, we recommend using 3M dual-lock MP3560 tape (or similar product, meant for outside use and resistant to higher temperatures) mounted with no more than 8" between each strip of tape to ensure secure attachment."

Polycarbonate Panels and Installation PDF:

https://www.coastalclimatecontrol.com/i ... p/95699298

https://www.coastalclimatecontrol.com/i ... ctions.pdf

ABS Plastic Brackets:

https://www.solara.eu/products/mounting-systems/

Compound,

Very nice solar panel installation. The raised height allows cooling and no shadows from the small kitchen vent. The sloped sides and the side rails are nice.

Some photos of the two semiflexible Solbian solar panels in front of Hemi.

Westy is dirty and silver paint is peeling--ignore. The solar panels have also faded over time but are not delaminating (a problem for some semiflexible panels).

Can see the 3M Dual Lock adds thickness around the edges. From view from top, can see that more strips should have been added to middle of panels to prevent dipping. Can see that passenger side solar panel was trimmed so centerline would touch. The solar wires prevent the solar panels from touching the Heki spoiler--of wires exited from the side, you could push the panel closer to spoiler. The dirty blotch at the front of the solar panels is a weephole gap for any water to run out from under the panels.

More.

Great pictures and hints OldWest, especially about scaffolding I really have to avoid another fall.

I've also ordered the panels now and will report back when I have mounted them (after my right foot has healed enough).

If you try to glue the solar panels to front, it'll be ugly with puckering on the edges and a pain to remove. These were removed.
3M Dual Lock allows for more variability along the edges--thicker in some areas and more compressed in other areas. But, as the 3M Dual Lock has thickness, need to support the middle. In this photo, we didn't provide enough support in the middle (just a couple of squares) and should have run strips between the cells--leaving space for water to run out.

Think the 3M Dual Lock is 2 inches wides around perimeter (think we had 1 inch wide and just put side by side). The edge nearest the spoiler was only 1 inch plus a piece under the solar wire junction.
Look at how shiny the solar panels were in 2013.

Scaffolding on each side, wood plank supported by scaffolding across hood, and front end on ramps.

We rented the scaffolds. You don't need scaffolding that wide but that's what the rental place had. Put some cheap pool noodles on scaffolding pipes closest to Westy to be on the safe side from scratching.

Believe the top of scaffolds is 5 feet which is plenty high to reach everything. Ladders are too unsteady and can dent fiberglass top. Stepladders narrow toward top so you're farther away as you climb.

Heki skylight can be removed from inside--after removing dome, can tilt dome and bring inside the Westy through skylight opening.

Hey Old West,

thanks for your reply, but the work was already done from the former owner, all by himself.
Im am very thankful for that

Thanks for the helpful Pictures.

Greatings in the USA

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