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Adventures in solar pre-wiring and drilling through roof

solar install

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#1 Ruck_and_Roll

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Posted 29 July 2019 - 05:02 PM

I have seen a few posts on this http://www.wanderthe...ed-solar/page-2, and attempted to follow Craig's install http://www.wanderthe...mount/?p=185595 but the crux is "what to do with solar pre-wiring when you do not have an external plug with roof access?"

 

1.  E-mail FWC for solar pre-wiring location- Unfortunately FWC was unable to provide me location based on serial and original owner but did give me an approximate location.  So that was a no go.

 

2.  Based on recommendations from this forum, I used a wire detector and found the wires going towards the push board, but not really terminating near there.  I could not feel a junction box.  I basically used the last know detected area and cut a small home in the fabric and then drilled about an inch hole up into the roof.  Alternatively, I could have drilled from the roof but this seemed a little more risky as I could not approximate the wire location from above.

 

The good news was that I found the wires.  They were pretty well deeply embedded in the insulation.

I could not see where the wires terminate (or if there was even a SAE plug) so I cut the wires and ran them through the hole in roof and marine sealed a junction box.

 

The bad news is I have a small slit in my fabric.  I stuffed some insulation up there. I think I can cover it nicely with a piece of decorative wood trim placed horizontally (similar to what is vertical).  

 

My thought is to check polarity and directly attach male/female MC4 connectors to the 10 AWG wires and then hook the panel directly to that, bypassing any need for SAE plug.  I am starting with just one panel.  Has anyone tried this before?  

 

 


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#2 Dirt Rider

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Posted 29 July 2019 - 08:47 PM

Does anyone know when FWC started installing pre wiring in the Grandby? I have a 94


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#3 ckent323

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Posted 30 July 2019 - 02:19 AM

I used a Permatex Vinyl and Leather repair kit to patch the cuts in the headliner. It worked pretty well and the small remaining defects are hidden under the ceiling board that my lift struts are attached to.

I will recover a picture or two of the vinyl repair and the ceiling board from my archives to post.


As I recall the pre-wiring started sometime between 2004 and 2006 depending on the model.


Craig

Edited by ckent323, 30 July 2019 - 02:22 AM.

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1993 Dodge Cummins W-250 Club Cab long bed, 2007 FWC Keystone


#4 Stan@FourWheel

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Posted 30 July 2019 - 07:45 PM

Does anyone know when FWC started installing pre wiring in the Grandby? I have a 94

 

2005 ish"  + or -


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#5 Ruck_and_Roll

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Posted 14 August 2019 - 06:47 PM

Finished the install yesterday evening.  Everything went smoothly although not the prettiest job.  Ended up using the Yakima rail kit and aluminum angle for mounting.  I used RV/marine sealant I got at Home Depot with the housing from Amazon.  I bought a MC4 connectors kit from Renogy and used that for the terminal ends of the FWC pre wiring.  The only hiccup was the initial addition of adding MC4 connectors, I did not  install them correctly the first time and didn't realize that not only were there male/female connectors but the inner metal tubes also had male/female differences.  There are better youtube videos on the MC4 connectors than what Renogy posts.  But all is well and excited to see it is working.  Using the a Victron 75/15 controller and going to add the display this evening.  The only thing I would do differently is likely adding a lower profile housing so I could slide the panel over it and "hide the housing."  Will likely move the connectors underneath the panel.   

 

solaronroof.jpg


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2021 Ford XL SuperCrew HD Payload Pkg

2008 FWC Hawk

Western Colorado, USA

Instagram: @lukeyfiasco

 


#6 ckent323

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Posted 14 August 2019 - 11:15 PM

Ruck and Roll,

Looks good (although the picture is a bit small to see much detail. ;-)

Which roof entry gland did you decide to use? Renogy?


Regards,

Craig

Edited by ckent323, 14 August 2019 - 11:17 PM.

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1993 Dodge Cummins W-250 Club Cab long bed, 2007 FWC Keystone


#7 Ruck_and_Roll

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Posted 15 August 2019 - 05:46 AM

I will try reposting an updated photo.  

 

I did use the Renogy housing.

 

I think this one looks a little more "low profile" based on the listed dimensions:

 

https://www.amazon.c...HBA185PVFEESSZA


Edited by Ruck_and_Roll, 15 August 2019 - 05:46 AM.

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2021 Ford XL SuperCrew HD Payload Pkg

2008 FWC Hawk

Western Colorado, USA

Instagram: @lukeyfiasco

 






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