After asking, “Are we sure about this?” a few dozen times, we drilled the hole. As Gordon drilled, rubber TPO, luan plywood, several inches of closed cell foam insulation, and more luan plywood came up. We knew we needed to drill this hole, but it was still somewhat terrifying to see it happen.
Above: Michael Emerick applying Sikaflex 715 around the 8 gauge wire
Above: Caulking the junction box tight to the roof
With the hole drilled, the 8-gauge wire was fed into the camper and underlying wardrobe through the hole. Then Sikaflex 715 was applied into the hole at the point where wire emerged.
Above: Gordon positioning the junction box after Sikaflex has been applied
Sikaflex was then applied to the bottom edges of the junction box before the junction box was placed into position above the 8-gauge wire. The junction box was then screwed into the roof with stainless steel screws. Once the screws were in, Sikaflex was applied to the base of the junction box, and smoothed out for consistent coverage by hand.
Securing the solar panel to the roof was next. Gorilla tape was used to hold the panel wiring to the inside upper panel. Then the panel was carefully flipped over and placed into its previously determined position on the forward driver’s side.
Above: The solar panel bracket feet being secured onto the roof
Again, stainless steel screws were used with a dab of Sikaflex 715 to secure the panel to the camper’s roof. When the screws were in, Sikaflex 715 was used to cover the solar panel bracket feet.
Next: Read about how Truck Camper Magazine and Team Emerick install the Zamp Controller, finish the install, and test the solar system. Then Gordon and Angela kill two batteries, and learn an expensive lesson; Installing A Solar Controller.