After my last trip I noticed my solar panels were not working anymore, tested them and my right side had not output. I also noticed it had a big bulge to it. Luckily I have some other panels to replace. I went to take the first panel off and it seems like the bulge was actually between the honeycomb and the white plastic layer. So now I have a big missing section. What’s the best way to go about fixing this? Or is my best option just replacing the whole roof?
Cheers in advance!
I’ve wondered about the eventual need to replace a roof panel. Check with GFC and see what they recommend, but I’ll be surprised if there’s a way to permanently patch the old roof panel. Please let us know how you resolve it.
Since the failure was directly under the solar panel, I wonder if the adhesive weakened the roof, or if heat generated by the solar panel degraded it.
That’s what I was wondering too, whether the solar panel created heat which caused the issue. However, there are plenty of GFCs around with solar panels “glued” to their roofs with no issues
Man, that’s a bummer. Looks like the protective layer delaminated from the honeycomb. I think all you can do is replace the whole roof panel.
For what it’s worth, I had Sunpower flexible panels on my roof, mounted with all-around VHB and they heated up to 160F in places, and also trapped water underneath which helped them conduct heat into the roof. When one of them finally died, it got even hotter than that, actually smoked/sizzled until it burned through.
I have no idea if this is a cause in your situation, just adding this as a data point. Hope you find a reasonably clean way to fix this.
No issues … yet.
Long term, I don’t believe thin-film panels offer enough advantages over bolting a large, rigid panel on top of a GFC. Mounting directly to the roof puts a lot of heat into the GFC roof panel for long periods. Even if a rigid solar panel is installed with less than its recommended minimum air gap, it can still be ventilated. Just my opinion, of course.
Yea I think you’re all right, the panels definitely built some heat, I think that plus moisture caused the delamination. When the blister popped when I was looking under the panel a decent amount of moisture was underneath.
I was just about to pull the trigger on a CIGS flexible panel - this changed my mind!
You have a brand you recommend for the rigid panel?
Nothing in particular, but it pays to check their impact and wind resistance specs. Buying from a local supplier should reduce shipping costs. Here’s a good site for researching available options. Skip bifacial panels.
I bought an LG residential panel. I plan to keep it off the roof, but under some Yakima bars so I can still carry cargo. Nesting it in a frame and attaching it to the GFC frame’s T-slots should work.
Not sure solar except portable panels makes any sense. I have 300 watts CIGS ($675 current) on the roof charging a Bluetti AC200MAX w/B230 expansion battery (≈ 4096 watts) a Bluetti 200 watt folding panels when camped in the woods and a Pecron DC to DC charger (noisy- no Bluetooth app would buy the Bluetti instead)
Mark (& Teresa)
Hampstead Maryland
• Purpose Built Adventure Rigs © •
Ford Ranger FX4 - GFC Camper V2 # 1919
Nissan Xterra Off-Road - Camp Rig & Kia Soulverlander
Jake I have the BougeRV CIGS solar panels which came with the tape option. They suggest for removal using a piano wire under to get the tape to release and remove the panel.
Couple ideas come to mind for a “Temporary Repair”.
We have a good friend who has a V1 #386 and has been running the (2) LenSun 200watt panels sitting on vinyl on his roof for some time (East Coast MD). Vinyl is what he does and happens to be the US LenSun Rep. Ofcourse they say not to install it on vinyl. But all the LenSun solar hoods are over vinyl.
Mark (& Teresa) Out Of Office Camping
Hampstead Maryland
• Purpose Built Adventure Rigs © •
Ford Ranger FX4 - GFC Camper V2 # 1919
Nissan Xterra Off-Road - Camp Rig & Kia Soulverlander
you’re gonna be fine with Bouge RV CIGS.
I also have a bulge in the roof on the inside. that is my own doing though I was removing VHB using a heat gun to help the process, and wasn’t paying attention in one particular spot.
should I just pop a hole on it?
Good to know! I was finally planning on adding that kind of solar panel, might need to rethink this.
The Shade stopper flexible solar panel, with their installation kit has been working good for me.
I might have some helpful information as I experienced 2 of the same issues you mentioned; dead solar panel and bubbled roof panel. I will attach a screen shot of the conversation that GFC emailed me.
Regarding the solar panels, I own 2 Lensun 150w panels. I recently noticed my panel output was about 50% less than normal and without testing, I determined 1 panel was dead due to a ‘burnt’ looking section. My research has shown a cell failed, whether due to heat or other factors I am unsure. I plan to remove both panels and upgrade to Sunflare panels due to their longer warranty and ‘bypass diodes’ which will help in semi-shaded areas.
I’m crossing my fingers that I don’t have the same results with removing the panels from the roof as I taped them with VHB.
sweet!
now i gotta go find a 5mm needle or something lol
I also had a large bubble but mine was on the inside and outside, and I have never had solar panels on. Camper installed in 2021. I had them replace the roof panel when I did the new tent install. They charged me for the roof panel but not the labor since they removed it with the tent install. When they saw my bubble, they said the small hole would not have worked.
How much did they charge for the roof panel?
They charged $300.
