Renogy Flexible Solar Panel Install
How to Install Flexible Solar Panels on a Camper Van (DIY Guide for Transits, Sprinters, & Promasters)
Converting a van into a camper means making smart solar power choices. If you're planning a camper van solar panel install, flexible panels can be a great lightweight, low-profile option. In this guide, we’ll show you how to install flexible solar panels on a van step by step, using Renogy 100W flexible solar panels and a no-drill mounting system.
Why Flexible Solar Panels for a Camper Van?
We compared flexible vs. rigid solar panels and chose Renogy flexible solar panels for these reasons:
✅ Lightweight – 70% lighter than rigid panels, improving fuel efficiency.
✅ No Drilling Required – No need to put holes in our van’s roof or build a bulky rack.
✅ Stealthy Design – Low-profile look makes it less obvious that it’s a camper.
✅ Curves with the Roof – Ideal for the slightly curved Transit van roofline.
The trade-off? Flexible panels are 5-10% less efficient than rigid ones (16-18% efficiency vs. 21%). Plus, direct mounting can trap heat, reducing performance and lifespan. To fix this, we designed a custom airflow mounting system to keep them cooler.
Materials We Used for Our Van Solar Panel Install
🔹 Renogy 100W Flexible Solar Panels – We have 4 panels, totaling 400W of off-grid power.
🔹 Clear Polycarbonate Wall Panel – Used to create the mounting base.
🔹 Smaller Polycarbonate Sheet – Another option for mounting just 1 panel.
🔹 48” Aluminum T-Track Rails – Secures the panels to the van roof.
🔹 Vinyl Lattice End Caps – Protects edges and reduces wind lift.
🔹 Sikaflex 715 – Heavy-duty adhesive for securing panels & tracks.
🔹 Hardware – Stainless steel bolts, nuts, washers, and lock washers–match panel grommets
Step-by-Step Guide: Installing Flexible Solar Panels on a Van
1. Build the Polycarbonate Mount
✅ Cut the polycarbonate sheet to match the height of each panel but 3 inches narrower to leave room for T-Track rails.
✅ Cut a small rectangular channel out of the middle (a few inches from the top, extending to the bottom) for better airflow.
✅ Attach the polycarbonate sheet to the panel using Sikaflex or another strong adhesive.
2. Attach Vinyl Lattice End Caps
✅ Cut end caps out of the vinyl lattice to fit the front and rear edges of the panel.
✅ Front cap: Notch out corners for front grommet bolts & wiring connectors.
✅ Rear cap: Cut to fit the insulated layer width and notch out airflow & drainage sections.
✅ If the fit is tight, slightly compress the polycarbonate sheet to ensure a snug fit.
3. Mount the Solar Panels & T-Tracks on the Roof
✅ Carefully carry the assembled panel up to the roof.
✅ Position the T-Track rails along the edges of the panel.
✅ Mark placement with a sharpie for accurate installation.
✅ Clean the roof & T-tracks thoroughly with acetone or rubbing alcohol.
✅ Apply Sikaflex, strong marine adhesive, or Eternabond tape to bottom of T-Track rails.
✅ Press and hold firmly to ensure a strong bond.
✅ Seal around the T-Track base with Sikaflex for added strength & a clean finish.
5. Attach the Solar Panel
✅ Slide bolts into the T-tracks and align them with the panel’s grommet holes.
✅ Secure with stainless steel nuts & lock washers, tightening them down.
Final Thoughts: How Our Flexible Solar Panel Setup is Performing
Installing Renogy Flexible Solar Panels made our van build lightweight, sleek, and drill-free—a perfect fit for off-grid adventures. After 6+ months on the road, our van solar setup is holding strong! The panels have endured rain, wind, and extreme heat, and they’re still charging our battery bank efficiently.
A huge shoutout to Brian from RV with Tito, whose excellent video inspired our no-drill mounting system! He had a different brand of solar panels. So our hardware for securing the panels is a little different from his.
If you’re planning a camper van solar panel install, we highly recommend this setup! Check out the full list of materials above to start your own DIY van solar project.💬 Got questions about solar panels or van builds? Drop a comment below—we’d love to help!
Affiliate Disclosure – Keeping the Van Rolling!
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