Application note
Two Panels on a Caravan Roof Without Drilling
A caravan owner planned to DIY-install two 80 watt polycrystalline panels on the roof of a 21 ft 6 in van. The question raised on the forum was whether to buy two sets of aluminium flush brackets and bolt them down.
The Challenge
The conventional answer — two sets of aluminium flush brackets — is cheaper on parts and more expensive on everything else. It means drilling the roof, fitting screws, and sealing every penetration. If the panels ever come off, the roof surface is damaged where the fixings were.
Pain Points
- Drilling holes in a caravan roof for eight or more fixing points
- Labour: every hole has to be drilled, sealed and checked
- Permanent damage to the van surface if the array is ever removed
- A sealing job that has to be inspected for the life of the vehicle
What We Recommended
Step 1
Use the ABS plastic solar panel mount range instead of aluminium flush brackets.
Step 2
Bond the mounts to the roof with adhesive — no drilling, on an RV, caravan, camping vehicle, motorhome or marine roof.
Step 3
Corner moulds on all four corners of each panel, with a spoiler set along the edges given the panel size.
Step 4
Route both cable legs through one bonded IP65 double-gland entry box rather than two separate holes.
Result
What Changed
No holes anywhere in the caravan roof
Substantially less labour than drilling and sealing eight or more fixing points
The mounts double as wind deflectors and hold the air gap under both panels
The installation can be reversed later without leaving fastener holes
Products used
Hardware Referenced in This Note
BS09009-BSolar Panel Corner Mount 150 mm Black
A four-piece ABS corner set that bonds any 150 mm-lateral aluminium-framed panel to a roof or deck without drilling.
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BS09009-WSolar Panel Corner Mount 150 mm White
The white version of the BS09009 corner set — the usual choice on white caravan and motorhome roofs.
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BS090017-BSolar Panel Side Mount 180 mm Black
A two-piece 180 mm ABS spoiler set that carries the side of a framed panel and can be painted to match any roof.
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BS090017-WSolar Panel Side Mount 180 mm White
The white 180 mm spoiler pair — the side bracket that goes into the white caravan mounting kits.
View details →Questions
Frequently Asked Questions
Was the aluminium bracket option wrong?
Not wrong — cheaper on parts. But it costs much more labour, needs holes drilled in the roof, and damages the surface of the van if the panels are ever removed.
How are the ABS mounts fixed instead?
With adhesive glue. No hole is drilled in the roof of the recreational vehicle, caravan, camping vehicle, motorhome or marine roof.
Does this work for two panels as well as one?
Yes. Each panel gets its own set of mounts; the saving in labour scales with the number of fixing points you would otherwise have drilled.
A Similar Job to Quote?
Describe the vehicle or vessel, the panels and the roof construction. We will tell you what to order and what to bond it with.