The mounting assembly for the solar panel consists of a rigid foam core covered with three separately applied layers of fiberglass. It has sticky back foam tape applied to the top and bottom surfaces. It is pinched between the aluminum framework and the roof top luggage rack with 8 hasps that are bolted to aluminum plates welded to the inside perimeter of the aluminum framework (Solar_D). The axles for the nylon roller wheels (Solar_C) consist of a hex head stainless steel bolt a stainless steel nut and a stainless steel aircraft type nut attached to an aluminum plate which is secured to the aluminum framework with stainless steel bolts and aircraft type nuts. An aluminum hitch pin allows removal of the solar panel from the aluminum framework.

 

The solar panel is recessed into the aluminum framework and locked down with latches (Solar_D). A stainless steel cable is routed from the fulcrum point of one latch down through a drain hole, out from under the luggage rack, through a 12 inch length of rubber hose (which is exposed for access at a point just in front of the pop-top latch mechanism, between the pop-top canvas and the luggage rack) then back under the luggage rack, up through the drain hole on the other side and connected to the fulcrum point of the other latch. To move the panel out over the windshield, pull on the release cable and lift the panel up a few inches, grab both handles, tilt the panel to a 45-degree angle and slide the panel down over the windshield. During this procedure power from the panel is uninterrupted.

 

Charging current from the solar panel flows down through one of the drain holes in the roof luggage rack, then through holes drilled in the metal roof (lined with grommets and sealed with silicon sealant), then down though a hole cut in the ceiling above the drivers seat (Heat_D), then to a DPDT (double pole double throw) toggle switch mounted in the cabinet under the kitchen sink, then to the PV terminals on the controller, then from the BATTERY terminals of the controller to the ammeter, then through a 10 amp panel fuse and finally to the battery through a 30 amp inline fuse. As the battery approaches full charge the Morningstar SunSaver-10 photovoltaic system controller tapers off the current supplied to the battery to prevent over charging (Battery_B).