Project: Install a solar panel to my RV (Roadtrek 170 Popular) for around $300 dollars

Project cost:  $304.12

I wanted to add a solar panel to my Roadtrek 170 Popular as this would allow me to extend my boondocking camping trips and the same time do it for around $300 dollars.  As my RV is not equipped with a generator (pretty expensive option to add one at this point) and running the engine just to charge the battery is not very practical, I figured adding a solar panel was really the best way to go.  When considering my options I decided not to permanently mount it on the roof as I prefer to park my camper van in the shade. Also, because of the limited roof area on this model, I would have had to mount it sideways along the back of the van creating greater air resistance while traveling. With my gas mileage averaging around 16 mpg I certainly did not want to add anything that would contribute to its drop nor did I want to take the chance of creating a whistling sounds as the air passed over the panel. So if I wasn't going to place it on the roof, the challenge became where to store the solar panel when not being used in the smallest of the Roadtrek models.

This challenge was solved when I realized I could place a solar panel (47 x 1.4 x 21.3 inches) in the very back of the van in the underneath storage area accessible from the rear doors.  Basically, what I did was add a couple of shelves on to this back storage area so I could minimize the area it took up and at the same time protect the solar panel itself.  Note the felt padding I added to the wood pieces to minimize it bouncing around on the shelf.  When creating the shelf for the solar panel to sit on I also removed the back seat belts as i did not want the solar panel glass breaking from the protruding seat belt bolts sticking down.  This was fine with me as I have the additional seat behind the passenger captain chair and my back area had been converted into a permanent bed so I would not use these seat belts anyway.  I am sure there are other ways to work around the bolts like lowering the shelf if you needed to keep the seat belts or pointing the glass down towards the ground.  I wanted the glass on the panel to be facing up so as it minimize the chance of something below the panel bouncing up and breaking the glass, but you could face it down (with care as to what you have below it) and this could be another work around.

 

 Near the van doors I added a rubber stopper for one side and a Velcro sling for the other side.  This made for easy removal of the solar panel when I wanted to plug it in. The rubber stopper I bolted in place and secured the nut though the opening in the side of the door panel.

  Speaking of plugging it in, I decided to create an external power connector underneath the van so I could keep my van doors closed during those times I would be charging the battery.  Don't want to make it too easy for nature to find its way into my van.  I ran the cable through the battery compartment on the right side of the van and bought a dust/moisture cover to keep the contacts in good condition when not in use.  The cable I bought was originally 50 feet. I needed to cut this in half as one side had the female plug and the other side the male plug so I ended up with a cable approximately 22 feet in length (3 feet was used to connect the external connector cable to the terminal strip.  This length still gave me plenty of locations to place my solar panel.  Usually I just placed my panel against one of my camping chairs when charging though at some point I may build a stand out of PVC pipes.

 

 The parts used for this project where as follows:

 

Item Model Qty Cost per Item Total Solar Panel RENOGY 100 Watt 100w Monocrystalline Photovoltaic PV Solar Panel Module 12V Battery Charging 1 179.99 179.99 Volt Meter Mini Blue LED Digital Volt Meter 4.5~30v for 9v 12v 24v 1 10.38 10.38 50 ft MC4 Cable Instapark® CBL50 12-Gauge MC4 Male to Female Solar Panel Extension Cable, 50-Foot, UL Listed 1 34.99 34.99 Charge Controller Instapark® PRS-1515 PWM 12V/24V 15 Amp Solar Power Charge Controller, 180W/360W 1 27.95 27.95 Power Connector Anderson SB50A 2 connector kit 1 8 8 Dust/Moisture Protector Dust cover for Anderson SB50 connector 1 4 4 Terminal Strip 22-10 guage RadioShack 12 position jumbo 274-0677 1 4.33 4.33 Battery Cable 4 feet 10 guage wire Red and Black from West Marine  2 3.25 6.5 Ring Term 3/8 Solderfill Ring Term 2 count from Auto Zone 1 4 4 In-Line Fuse Holder ATO Fuse holder with protective cover from Pep Boys 2 3.99 7.98 ATO Fuse 15 Amp ATO Blade from Pep Boys 1 3.5 3.5 Rubber Stopper Size 1 11/16 from Lowe's 1 2.5 2.5 Felt Padding Lowe's 1 6 6 Bolts & Nuts Machine 8-32X1 8 count @ Lowe's 1 1.5 1.5 Bolts & Nuts 1/4-20X2 1/2 2 count 2 1.25 2.5 Total 304.12
Note: the wood pieces I did not have to purchase as I had these lying around. Want to thank Wilton Hart from http://windsurf.mediaforte.com/roadtrek/solar/Roadtrek_Solar_on_the_Cheap.html for his wonderful article and his information on the power consumption used by the various components in a Roadtrek.  His article helped me figure out how much energy I needed for my typical usage.  I recommend you read his article.  Bottom line for me is that 100watt should take care of most of my energy needs assuming I keep the solar panel in the sun for around four to six hours when recharging. In my energy plan, I will not be using the A/C nor microwave though the later is possible with a large enough inverter.  I converted all of my house battery lights to LED to lower my energy consumption and one of my big energy uses is my 12volt LCD TV/DVD which I installed a couple of months earlier and/or the fan during the hotter summer months.  On colder days running the propane heater can use up a lot of watts so its use has to be regulated. Hope this blog helps with your RV solar project.