Solar Panels on Rhino-Racks

[Boxster1971]

I promised fspeier more details on my solar panel installation on Rhino-Rack Cross bars. I thought Id start a new thread to keep from polluting the tread on bought Interstate 2012 - needs a lot of parts.

Here are few more photos. The brackets I made to provide a mounting point next to the Awning are not an original idea by me. I copied the idea from a single photo posted by the Sprinter-Store some time ago. First photo is of the aluminum flat pate adapters made by the Sprinter-Store.
The rest of the photos attached are shots showing some details of the Rhino-Rack legs attached to the brackets when I was fitting the parts. All the final install fasteners were stainless steel with nylock nuts and anti-seize lube added.

[Boxster1971]

This post has some additional photos of my fit checks of the Rhino-Racks on the roof of my van. The third photo shows the clearance from the bath vent using my level across the rack bars. The last photo is the new lower 360 Siphon vent I installed to clear the solar panels. I didn't worry about the white color of the new vent compared to the original black as it is not visible.

[Boxster1971]

These are photos of the trimmed for length Rhino-Rack bars. Then the installation of the first two 100 watt panels in 2014. The last photo is the final four 100 watt panels installed in 2015.

[lewster]

Nice work!!

I see you reversed your MaxxFan. Be real careful that you don't leave it open when you travel, as the cover WILL be sucked right off the roof. I have seen it happen more than once!!!

[toskeysam]

Looks great! Curious about your route for wiring to the controller.

[Boxster1971]

Originally Posted by lewster

Nice work!!



I see you reversed your MaxxFan. Be real careful that you don't leave it open when you travel, as the cover WILL be sucked right off the roof. I have seen it happen more than once!!!

Yes I never leave it open while driving. I assumed it would get ripped off in the speeds above 30 mph.


- - Mike
2013 Lounge EXT on 2012 Sprinter

[amirm]

Very nice! When you moved the antenna, did you have to plug any holes? Not sure how that is mounted.

[Boxster1971]

Originally Posted by amirm

Very nice! When you moved the antenna, did you have to plug any holes? Not sure how that is mounted.

Yes there were holes to fill for both the old 50 watt solar panel (4 holes) and the TV antenna tripod mount (3 holes). I used Sika Sikaflex 221 sealant that I got from Airstream. I filled the holes with sealant and then placed a small patch of duct tape over the holes and covered the patch with sealant.

The newer Interstates have a small TV antenna that might be easier to relocate. I also considered going to a Winegard Rayzar like the link below. But the now discontinued black disc Omni antenna works well and I wanted to keep it.

http://www.winegard.com/rayzar

[amirm]

Thanks. I still have the same fear I had when I had to drill the first hole into my boat. Seems less critical with an RV roof as it is not as visible as a boat and consequence of a leak as dramatic!

Did I read in another thread that those roof rails don't work in the newer Interstates?

[JayP]

Boxster,
Your conversion was my inspiration to do mine, thanks for sharing your posts last year.

jp

[lewster]

Originally Posted by amirm

Thanks. I still have the same fear I had when I had to drill the first hole into my boat. Seems less critical with an RV roof as it is not as visible as a boat and consequence of a leak as dramatic!

Did I read in another thread that those roof rails don't work in the newer Interstates?

No need to drill any holes to mount those panels!!!

I mount 4 X 100 watt panels on almost every AI installation that I do and there is only ONE HOLE.....and that's to get the solar charge line into the coach from the bottom of the roof combiner box.

VHB tape and SikaFlex have all of the bond strength that you need for a Sprinter's roof.

PS: I don't use racks either!!

[Boxster1971]

Originally Posted by amirm

Thanks. I still have the same fear I had when I had to drill the first hole into my boat. Seems less critical with an RV roof as it is not as visible as a boat and consequence of a leak as dramatic!

Did I read in another thread that those roof rails don't work in the newer Interstates?

I think Airstream stopped ordering their base Sprinters with the roof rails from Mercedes. But there are a lot of ways to mount Solar panels on the roof of your Interstate. Lewster mentioned one of them in his post above.


- - Mike
2013 Lounge EXT on 2012 Sprinter

[lewster]

Nope!

No more rack rails on the newer Interstates. The contact points are still there as these are standard with every Sprinter body. You would have to order the rails from Benz and then install them into the contact points.

[Boxster1971]

Originally Posted by JayP

Boxster,

Your conversion was my inspiration to do mine, thanks for sharing your posts last year.



jp

Nice job! Looks like you used the AM Solar mounting feet. I would use those if I ever do another solar install on an RV. My installation got a little too complicated. I blame my Aerospace background for over designing it, when I could have just done it like yours.


- - Mike
2013 Lounge EXT on 2012 Sprinter

[Boxster1971]

Originally Posted by toskeysam

Looks great! Curious about your route for wiring to the controller.

From junction box on roof I dropped 6AWG cables from AM Solar in the void behind the sink in the bath. Then over the passenger side rear wheel well and into the area under the lounge seat where I mounted the controller near the battery box.


- - Mike
2013 Lounge EXT on 2012 Sprinter

[amirm]

Originally Posted by lewster

No need to drill any holes to mount those panels!!!

I mount 4 X 100 watt panels on almost every AI installation that I do and there is only ONE HOLE.....and that's to get the solar charge line into the coach from the bottom of the roof combiner box.

VHB tape and SikaFlex have all of the bond strength that you need for a Sprinter's roof.

PS: I don't use racks either!!

Always showing off I see!

Seriously, do I recall you live in Oregon part of the year? If so, what is your outlook on solar in the pacific northwest? My one 100 watt panel produces next to nothing as soon as it clouds over. And this is summer time.

What do folks get out of four panels?

[Boxster1971]

Originally Posted by lewster

No need to drill any holes to mount those panels!!!



I mount 4 X 100 watt panels on almost every AI installation that I do and there is only ONE HOLE.....and that's to get the solar charge line into the coach from the bottom of the roof combiner box.



VHB tape and SikaFlex have all of the bond strength that you need for a Sprinter's roof.



PS: I don't use racks either!!

I agree 100%. I would not recommend racks and would not use them again. I now realize the the simple mounting feet from AM Solar is the absolute best way to add solar panels to your Interstate. VHB tape plus Sikaflex is a very strong bond to the roof.


- - Mike
2013 Lounge EXT on 2012 Sprinter

[southjk]

Awesome install

[southjk]

Originally Posted by lewster

No need to drill any holes to mount those panels!!!



I mount 4 X 100 watt panels on almost every AI installation that I do and there is only ONE HOLE.....and that's to get the solar charge line into the coach from the bottom of the roof combiner box.



VHB tape and SikaFlex have all of the bond strength that you need for a Sprinter's roof.



PS: I don't use racks either!!

Do you have any pics of how you placed the tape? Was it double sided applied to the underside?

[Protagonist]

Originally Posted by Boxster1971

I think Airstream stopped ordering their base Sprinters with the roof rails from Mercedes.

Originally Posted by lewster

No more rack rails on the newer Interstates. The contact points are still there as these are standard with every Sprinter body. You would have to order the rails from Benz and then install them into the contact points.

The sliding side door on an NCV3 Sprinter is taller than on the T1N Sprinters. So when Airstream started using NCV3 Sprinters for their Interstates, they had to relocate the awning from high on the side to on top of the roof… right where the passenger-side roof rail would be. So you could mount a rail on the driver's side, but you'd have to remove the awning to mount a rail on the passenger side.