DIY Roof Rack and Solar Panels

📋 Table of Contents & Overview

DIY Roof Rack and Solar Panels – Installation & Planning
Overall Electrical Overview
Additional LED High Beam & Reversing Light
Gallery & Detailed Shots
Download Documents (Electrical Diagram & Assembly Plan)
Products & Materials Used

DIY Roof Rack and Solar Panels

Installation of Solar Panels on the Roof of a Ducato, Jumper or Boxer
Roof Rack with Existing Awning

If you are planning to install solar panels on the roof of your van, there are a few things to consider. Here, I will show you how I mounted the solar panels on my Fiat Ducato (the same applies to Citroën Jumper and Peugeot Boxer) without gluing the panels directly to the roof.

The biggest difficulty was that an awning (Fiamma F80s) was already installed, and I did not want to dismantle it or buy new brackets. For this reason, I designed my own brackets and had them manufactured. See below.

Preparation and Materials

I did not want to glue the solar panels directly to the roof, as I already had good experiences with a roof rack from a previous conversion and square profiles (Bosch/Item). These are not only stable but also inexpensive.
I used 30x30 mm profiles. In addition, the roof rack offers the flexibility to mount additional attachments such as light bars, boxes, sandboards, and much more. This allows me to customize the vehicle to my needs and use it optimally for various purposes.

Fastening

I attached the profiles to the vehicle's original mushroom head bolts with suitable brackets.
Since the camper already had an awning mounted, and I did not want to remove it, I decided to use the Fiamma awning brackets themselves as attachment points. For this, I designed my own bracket and had it made from stainless steel.
The brackets for the solar panels themselves were also custom-made by my befriended metalworker. This ensured that everything was fitted precisely and stably.
Make sure to pay attention to the torque: The nuts on the mushroom head bolts must not be tightened with more than 4 Nm to avoid damage.

💡 Important Tightening Torque:

The nuts on the original mushroom head bolts on the vehicle roof must not be tightened with more than 4 Nm to prevent tearing out or damaging the roof mounts.

Wiring

I connected the solar panels in parallel. The difference between parallel and series connection lies in voltage and current:

Parallel:

In a parallel connection (see below), the voltage remains the same while the current is added. This means that each panel operates independently, which is particularly advantageous if a panel is partially shaded. The performance of the other panels remains unaffected.

Series:

In a series connection, the voltage of the individual panels adds up, while the current remains the same. This can lead to efficiency losses if a panel is partially shaded, as the entire series then produces less current.
Since we often travel in varying conditions, the parallel connection is the better choice for us, as it provides more consistent and reliable performance.

Solar Panels:

I chose the ECTIVE MSP S-Series because these solar panels offer higher efficiency and more advanced technologies. They are more robust and optimized for demanding environments, allowing for more flexible installation. Additionally, they offer higher power density (twice as many cells compared to regular solar panels) and better performance in low light, making them ideal for special applications. Despite the higher price, they offer better long-term performance and reliability.

Roof penetration

For the roof penetration, I used the Kathrein HDZ 100. This allows for flexible expansion of electrical components such as LED light bars, LED reversing lights, antennas, and more. The HDZ 100 provides a secure and weatherproof way to route cables through the roof without water ingress.

Conclusion

By using roof racks and square profiles, as well as the parallel connection of the solar panels, I have created a stable and efficient solution for energy generation on the roof of my van. The Kathrein HDZ 100 ensures that future expansions can be easily integrated. Now we are well-equipped for self-sufficient travel and have enough energy to enjoy our adventures.

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