Vanagon T3 Westfalia roof renovation w/ solar

[puchfinnland]

Early last spring I decided to take on the roof renovation,
on my list

Repair, modify, and repaint the luggage rack

Install 2 x 100w solar panels

Repaint the pop-top

Remove and replace the worn out flocking

Install a new canvas tent.

I started on the luggage rack, I wanted to modify it so they drain directly to the gutters, so not to collect leaves and twigs below. the center drain was deleted, I made sure the new drains tubes would in no way touch the body.

I used 3/8 ID PEX pipe, as the mold, as it came from a coil, I pushed all thread thru it to make it straight for the layup.

Thickened resin was first packed around the holes, followed by wrapping fiberglass mat around the tubes, this is a 2 person job.
_________________
ABYC marine master technician , EX European auto technician, new business- EASTCOASTWEST , custom work on campers, only systems, no mechanical

[puchfinnland]

With the tubes pulled out, a little filler was used to fair in the ends,

All the original cleat holes were filled and faired

Solid fiberglass sheet (G10) was laminated in as backing plates
_________________
ABYC marine master technician , EX European auto technician, new business- EASTCOASTWEST , custom work on campers, only systems, no mechanical

[puchfinnland]

Awlgrip primer was applied with spray, followed with Awlgrip Oyster White with flattening agent, applied with a 4" foam roller.

I chose flattening agent as gloss in my opinion was just right, I applied using a roller to mimic the original orange peel texture, which hides any warps in the fiberglass.
_________________
ABYC marine master technician , EX European auto technician, new business- EASTCOASTWEST , custom work on campers, only systems, no mechanical

[puchfinnland]

I found these stainless "footman loops" on amazon at a fraction of the cost compared to dedicated aftermarket suppliers .

Top was installed with stainless hardware from GW with plastic washers from local hardware store.


..to be continued shortly
_________________
ABYC marine master technician , EX European auto technician, new business- EASTCOASTWEST , custom work on campers, only systems, no mechanical

[[email protected]]

Spectacular, great idea on the drains.

[dhaavers]

Brilliant idea & top notch execution...nice work!

- Dave
_________________
86 White Wolfsburg Westy Weekender
"The WonderVan"
<EDITED TO PROTECT INNOCENT PIXELS>

[puchfinnland]

SOLAR PANELS

During the summer I found time between events to move forward,
I acquired 2 quality solar panels

Now I am only talking about "soft" panels, hard panels are clearly longer lasting and that's what you see on home installs.

So I install solar on boats quite often, and there is a winning formula for quality panels.

I try not to get into discussions on FB VOG about others choice of panels
I am currently a fan of the LENSUN 110w panel, it satisfies my 3 requirements
found on amazon or direct from their page.
http://www.lensunsolar.com/Flexible-solar-panel/Black-flexible-solar-panel?product_id=378



3 things make up a quality panel

1. ETFE top coating, its soft and UV resistant. PET is not long lasting and turns whiteish

2. SUNPOWER cells, these are currently the highest output on the market.

3. Fiberglass backing, is not too flexible and does not delaminate, also good bonding character. PET does not glue well, its too waxy a surface and too flexible, it will warp.



[url][/url][url][/url]
_________________
ABYC marine master technician , EX European auto technician, new business- EASTCOASTWEST , custom work on campers, only systems, no mechanical

[puchfinnland]

Now mounting soft panels on a roof can be done several ways,
I was not interested in just screwing them down.

Panels generate heat, (they are black) and this heat radiates right into your sleeping area.

I wanted to have a layer of air between them and the fiberglass roof, and I also needed to lift the panels about 3/8" 10mm to deal with the contours of the roof.

I decided to use "greenhouse polycarbonate panel"
I cut it into sections to allow as much heat to channel out when driving and when the roof is raised

I taped off the grid so my adhesive did not make a mess, I used a toothed spreader like for floor tiles to carfeully attach the tiles to the back of a sanded and cleaned panel.

the adhesive I recommend is GE SILPRUF SCS2000
I used black between the panel and the polycarbonate and white between the it and the roof,

_________________
ABYC marine master technician , EX European auto technician, new business- EASTCOASTWEST , custom work on campers, only systems, no mechanical

[jimf909]

Outstanding posts. Will you be refinishing the pop-top too? Thanks.
_________________
- Jim

[puchfinnland]

Next came the method of getting the wires into the vehicle

I could not find a purchase-able method for my idea, so I decided to create
these parts from G10 fiberglass the hole drilled is very tight so with a little sealant I should have no issue.

So I inserted a piece of wire while laminating so the hole remains clear.

I used thickened west system epoxy to attach the pieces

Unfortunately I did not take pics of the screw anchors I fabricated, it is slightly visible in this image, I used G10 fiberglass pieces,
and carefully drilled and mounted 1/4" Stainless Steel Pronged Tee Nut they were recessed, they were made on a drill press,
I wanted anchors that did not penetrate the roof and were epoxied on.
_________________
ABYC marine master technician , EX European auto technician, new business- EASTCOASTWEST , custom work on campers, only systems, no mechanical

[Steve M.]

Good Stuff going on here!

Moving the drains as you did is a great idea as i have found more than one Westy with the roof rusted right thru from the collection of wet debris collected under the cargo box.
_________________
This free advice is worth exactly what you paid for it.

There are seven days in a week. Someday is not one of them.

[puchfinnland]

This is the completed tiles on the panels

I allowed plenty of air gap around the anchors

Panels sitting in place, waiting for the roof paint job,
_________________
ABYC marine master technician , EX European auto technician, new business- EASTCOASTWEST , custom work on campers, only systems, no mechanical

[jimf909]

From the learn something new every day department...

G-10 Fiberglass, what is it?

https://en.m.wikipedia.org/wiki/G10_(material)
G-10 is a high-pressure fiberglass laminate, a type of composite material.[1] It is created by stacking multiple layers of glass cloth, soaked in epoxy resin, and by compressing the resulting material under heat until the epoxy cures.[2][3] It is manufactured in flat sheets, most often a few millimeters thick.

G-10 is favored for its high strength, low moisture absorption, and high level of electrical insulation and chemical resistance. These properties are maintained not only at room temperature but also under humid or moist conditions. It was first used as a substrate for printed circuit boards, and its designation, G-10, comes from a National Electrical Manufacturers Association standard for this purpose.

Decorative variations of G-10 are produced in many colors and patterns and are especially used to make handles for knives, grips for firearms and other tools. These can be textured (for grip), bead blasted, sanded or polished. Its strength and low density make it useful for other kinds of handcrafting as well.

_________________
- Jim

[Jake de Villiers]

Very impressive work!
_________________
'84 Vanagon GL 1.9 WBX
'86 Westy Weekender Poptop/2.5 Subaru/5 Speed Posi/Audi Front Brakes/16 x 7 Mercedes Wheels - answers to 'Dixie'
@jakedevilliersmusic1
http://sites.google.com/site/subyjake/mydixiedarlin%27
www.crescentbeachguitar.com
www.thebassspa.com

[dhaavers]

Very nice work! PF gots skillz...

- Dave
_________________
86 White Wolfsburg Westy Weekender
"The WonderVan"
<EDITED TO PROTECT INNOCENT PIXELS>

[puchfinnland]

G-10 Fiberglass
AKA

Arc-Resistant GPO3 Fiberglass Sheets and Strips
color- RED

avail from Mc-master Carr

https://www.mcmaster.com/standard-plastic-sheets
_________________
ABYC marine master technician , EX European auto technician, new business- EASTCOASTWEST , custom work on campers, only systems, no mechanical

[puchfinnland]

ROOF TIME!

Last Fall there was a small slack in work and my neighboring
business had an empty hall avail for a few weeks

I brought in the westy, stripped out the old canvas and removed the top

with the help of 3 people the roof was removed
As the next step involved bleach,
I bagged the van to protect it from splashes

Night and day, before and after scrubbing
_________________
ABYC marine master technician , EX European auto technician, new business- EASTCOASTWEST , custom work on campers, only systems, no mechanical

[puchfinnland]

I flipped it over and vigorously scrubbed the old flocking,
I noted in the summer, in the morning when still in bed the
original flocking was sticky to touch EEWWW!!

the roof was now clean enough to go into our shop to be re-done

Note the solar panel mechanical fasteners, screws were inserted to keep the paint out.

the roof was dusted with "Guide Coat" , which is like charcoal dust
this ensures you don't miss when sanding.

after wiping it down with acetone, the Awlgrip high build primer was sprayed

_________________
ABYC marine master technician , EX European auto technician, new business- EASTCOASTWEST , custom work on campers, only systems, no mechanical

[puchfinnland]

Roof in Primer

now that the primer is cured,
Its time to flip it and get to the flocking

Liberal amounts of acetone and scrapers makes the flocking come off easy,
the primer is very resistant to solvents.

_________________
ABYC marine master technician , EX European auto technician, new business- EASTCOASTWEST , custom work on campers, only systems, no mechanical

[puchfinnland]

5 hours later the Flocking was gone, note the trash can content
please note Acetone is really bad for your liver, please wear gloves!

So I will not be re-flocking, but using a marine hull liner material,
that said the vertical edges of the roof needs something like paint
there is turquoise in my new interior so I decided to splash a little color.
_________________
ABYC marine master technician , EX European auto technician, new business- EASTCOASTWEST , custom work on campers, only systems, no mechanical