I wanted a system which would assist with running the fridge and would top up the batteries when standing. I opted to add a solar panel behind each of the rear boot windows. This had the added advantage of blanking off the windows adding security for the boot.
Please note the solar panel system has been updated with full details here
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The first step was to create some 'blanks' for the rear windows to support the solar panels. To make these blanks I made a template out of newspaper following the outline of the window on the outside. |
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I then transferred this onto thicker cardboard which I placed up against the window on the inside. I gingerly trimmed this card with scissors until it was a good fit. |
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I then cut out two panels, using the templates, from 12mm MDF. I used this because I wanted a reasonable thickness to secure into. I sprayed the boards with satin black plasticote paint. This gave a nice even finish. |
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The solar panel was then mounted on the board and I fitted it in place after thoroughly cleaning the inside of the window. The solar panels are Sunsei 7.5 watt SE500s these produce 500 mA @ 15 volts in full sunlight. They link together easily and don't require a charge controller. On top of this they are almost a perfect size to fit the window. Between them they could provide up to 1 Amp of power when parked. The Engel draws 2.5 Amps so they wont run it, but they will assist and make the batteries last a bit longer. I will add details of the wiring below. Be warned if your thinking of doing this; they have upgraded the panels to 7.75W and changed the shape which means that they no longer fit. If you want this model you will have to search for old stock. |
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On the inside I added a support and made a small shelf to go over the auxilliary fuel tank. The cut out on the side support is to allow for the shelf support poles. You may notice that I have removed the rear seatbelts as these were right in the way of the shelf. In fact all I have done is undone the upper mount and 'recoiled' the belt into its lower mounting as it was too much hassle to remove all the trim to remove the inertia unit. If I had thought about it earlier I would have removed them at the beginning, but the shelf was a 'new addition' to the design. Like most of this system it has been 'designed' as it was built |
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All of this was then carpeted with the same B&Q value tiles. The shelf edges were edged to match the rest of the boot system. I added a net pocket bought from the local chandlers (similar ones are available from Mud Stuff and I will get any more from them as they are cheaper). The shelf will be used to house the 300 watt inverter, a 4 gang 12v socket extension and a 'charging station' for the variety of batteries that we will need.
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The rooflights are wired using 7 core trailer cable and enter the car via a gland just behind the offside alpine light. In addition a feed was taken from a the back of a reverse light to operate the rear work lights. This was then routed behind the trim and a 'slot' cut to allow the wires through. |
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The cable from the nearside solar panel was routed over the dog guard and connected to the new panel. The connection from this panel was then run into the 'bundle' and the blank fitted. |
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Here you can see the panel with the 'in' and 'out' connection wires at the top. |
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The blank was then carpeted to match the rest. The next step was the electrical installation. To be honest I wasn't looking forward to this. |
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However after a few hours stuck in the boot and continually climbing out to get the bits I'd forgotten the box, fuses and relays were fitted. All of the connections were crimped correctly. The relay 'holders' were mounted on the side of the enclosure using M4 nuts and bolts. I acquired the enclosure from City Electrical factors and the relay holders, relays and fuse holders from Panks auto electrical in Norwich. However you can get most of the parts online from VWP. I deliberatly added 2 additional slots for relays and fuses to allow for expansion in the future. I also added one of the small storage nets from Mud Stuff here. For more details on how I used these see here. |
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The two relays on the left operate the inner and outer front rooflights and the two on the right operate the rear work lights. There are two for this because one is operated by the dashboard switch and the other takes a feed from the reversing light. Either will switch the worklights on. I may also add another one here which would be operated by a manual switch at the rear. To give me a central wiring point I added two M6 bolts at the top to which I connected all the positive and negative feeds including the solar panel feeds. I ran two lengths of heavy gauge cable directly from the battery terminals, under the car and into the boot. I brought it in on the passenger side, because the new fuel tanks were in the way, and then fed it around the rear door to this box. This provides a direct feed but also connects the solar panels directly to the battery for charging. On the passenger side I took a split from the feed for the 4 way socket and inverter. More to come..... |
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The new 7.75W panels. More details to follow.
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