In this article I go over how I built a rack for my Renogy solar panels and attached the rack to my ProMaster. This rack is a nice middle ground for my van. I don’t have a ton of holes in my roof, the rack works well/feels sturdy, and it will allow me to upgrade later on if I want something nicer.
Materials/Tools Required
Weatherguard Promaster Roof Rack Rails
Renogy 160 Watt Solar Panels
Loctite Heavy Duty Threadlocker
Diablo Metal Saw Blade
Simple Green Cleaner
Kraft Paper
Blue Sea CableClam
Electrical Tape
Stainless Steel Carriage Bolts
Aluminum Angle
Stainless Steel washers, lock washers, and nylon nuts
Ram ProMaster Solar Panel Rack Steps
1] Fabricate 4 more plates that are similar to the weatherguard plates.
2] Install the weatherguard roof rails. Make sure to slide in your custom pieces for the roof rack before attaching the rails.
3] Cut the aluminum angle crossbars. Make sure to use a saw blade specifically made for metal if you are going to use a miter saw and also make sure they are clamped down securely.
4] Drill holes into the aluminum angle so that you can attach the angle to the solar panels. Use the existing holes in the solar panels to figure out where to drill the aluminum.
5] Drill holes into the aluminum angle so you can attach the angle to the roof rails.
6] Attach the aluminum angle to the solar panel(s) using stainless steel hex bolts, washers, lock washers, nylon bolts, and Loctite.
7] Drill a hole in the roof for where your solar panel cables need to come down. Try to put them as close to where your solar charger will be.
8] Drill out the holes in the rubber of the cable clam. You’ll want to start really small and then gradually get bigger drill bits. Pour water on the drill bit/rubber as you are drilling so you don’t burn/rip through the rubber.
9] Thread the solar panel wires through the cable clam.
10] Attach the cable clam to the van. Do a spray test to make sure you aren’t leaking anywhere.
11] Attach the solar panels / rack to the roof rails.
In the next article, we’ll start framing the van!