Are you curious about how to mount flexible solar panels on your DIY van conversion roof using your Renogy 100W solar kit or the one you put together yourself?! Well just follow this step-by-step guide, pointed out in 32 easy-to-follow steps from researching your solar panels set up, to buying the materials & tools, organizing your roof, and finally installing it so that it is ultimately theft-proof, lift-off proof, and heat resistant!

A flexible solar panel is a great option for curved van roofs like ours. We didn't have the option installing a traditional rigid panel, so we found these and they have worked flawlessly. We followed RV with Tito's advice and modified to our specific needs on how to mount flexible solar panels--I suppose each build is different & unique, but just wanted to share our variation!

We have had the panels on the roof for 8 months so far and we have yet to have a single issue. No one has attempted to steal the panels. There has yet to be a hot spot developed. And we have not sailed away with a wind gust at 80MPH!

This setup is perfect and reliable for any DIY mounting flexible solar panels on your van roof job! The only downside is, that if a panel did fail on us, we would have to remove some of the ceiling inside to access the bolts/screws. Not a complete buzz kill, but that was the sacrifice we decided on accepting to allow for these solar panels to be as theft-proof as possible--which was necessary because the Toyota Previa Minivan's roof sits so low to the ground!

Step-by-step process on How to Mount Flexible Solar Panels on DIY Van Conversion using the Renogy 100W Solar Kit
0:00 Intro
1) 0:52 Purchase all flexible solar panel material
2) 1:18 Cut coroplast
3) 1:20 Lay out materials to make sure you have them all
4) 1:57 Clean van roof
5) 2:00 Place coroplast on roof for checking roof layout
6) 2:04 Mark all other roof gear
7) 2:09 Remove coroplast and place solar panels on roof
8) 2:10 Cover with blankets
9) 2:13 Connect panel cables
10) 2:15 Mark holes for entry points and bolts
11a) 2:48 Drill holes for bolts
11b) 2:57 Remove Metal Shavings
12) 3:01 File newly drilled holes
13) 3:07 Tentatively secure panels to roof with front four bolts
14) 3:10 Mark the remaining bolt holes
15) 3:14 Remove panels and drill remaining bolt holes
16) 3:17 File new holes
17) 3:21 Treat all new roof holes with Rustoleum
18) 3:27 Mark and drill holes in Coroplast
19) 3:33 Apply Butyl Tape to both sides of each bolt hole on coroplast
20&21) 4:45 Add 3-4 strips of Butyl Tape to Each side of CoroPlast
5:05 *Butyl Tape Hack*
22) 5:49 Peel off paper tape cover and set solar panel on coroplast
23) 5:55 Set on van roof, flip up, and peel off paper backing
24) 5:59 Place bolts through grommets, press through Butyl Tape, and through drilled holes in roof
25) 6:06 Fasten washer, split lock washer, and Nylon lock nut – repeat for each bolt
26) 6:21 Cover solar panels with thick towels or blankets
27) 6:26 Install cable glands
28) 6:30 Connect solar panel cables and feed through cable glands
29) 6:35 Secure solar panel cables to roof with zip tie mounts
30) 7:07 Run Gorilla Tape along the front of each panel
31) 7:39 Cover each bolt with Gorilla Tape
32) 8:16 Leak test your job


We hope you learned something from this video and that you are one step closer to completing your DIY campervan conversion!

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