Install complete - what I'd do differently on my next RV solar setup

Nov 06, 2026 Last reply: 19 hours ago 3 Replies
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Finally got the last panel bolted down this weekend and everthing's charging. Six panels up top, wired in pairs to a single gland box on the back corner of the roof. Took me way longer than I planned because of all the stuff up there - two AC units, three vents, a skylight, and the antenna all had to be worked around. If I did it again I'd map out every obstruction with actual measurements before ordering panels.



Biggest tip: mount panels at the very edges where posible. Keeps them clear of the middle clutter and makes walking on the roof way less awkward. Also, run all your wiring through the gland box in one spot instead of drilling multiple holes. One entry point means one thing to seal and re-check later.



Use butyl tape under every mount foot, then screws, then more sealant on top. I skipped that on my first trailer years ago and chased a leak for two seasons. Also dry-fit the whole layout with painter's tape before drilling anything. Sounds obvious but I skipped it and ended up shifting one panel four inches after the first hole was alredy drilled.



For the wires themselves, leave slack at each panel. Roofs flex, panels expand in the heat, and a tight run will eventually rub on an edge somewhere. Zip tie everything down so nothing flaps, then check the whole run once more before you seal up.


Reading this brought back my own install last spring. I did four panels on a cargo trailer conversion and made the same mistake with the layout. My roof had a single low profile vent and I still managed to drill a hole in the wrong spot because I eyeballed the spacing instead of measuring. Had to fill it with lap sealant and start over, which meant buying a second tube of the self leveling stuff I already had half used from the vent install. Live and learn.

The one entry point for wiring is good advice. I ran mine through two separate glands because the panels ended up on opposite sides of the roof, and I regret it. One of the glands sits right where a strap from my roof rack crosses and I have to check it every couple months. If I'd planned better I could have gotten everything to one corner.

On the slack point, I'd add that it's worth actually clipping the wires to the panel frame with adhesive backed clips every foot or so, not just zip ties to whatever's handy. Mine sagged between two tie points the first summer and one jacket got chafed on the edge of the vent flashing. Found it because my charge controller numbers looked off one afternoon. Redid the run with clips and it's been fine since.

This makes me nervous about my own setup. I have a skylight in the middle of my roof too and I keep second guessing where panels can actually go around it. Does shade from the skylight frame or the AC units matter much, or is it only a problem if the shadow actually lands on the glass? I read somewhere that one shaded spot can slow down a whole panel but I don't fully get why that happens.

Agree on the butyl under every foot. I re-torqued all my mount screws after the first really hot week because the butyl compresses and the feet loosen up a bit. Found two that had maybe a quarter turn of slack. Another squeeze of sealant on top after that and mine have been dry through three winters now.

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