Camper Van Solar Setup Tips: Avoid Premature Failures & Weather Damage

When it comes to setting up solar on your van, a few small decisions can make a big difference in performance and longevity. Over the years, I’ve noticed a couple of common issues worth pointing out.

The first thing: junction box placement.
I recently pulled an older Overland solar panel off a van. It wasn’t a bad panel, but it was one of their early generations with the junction box mounted on top. After just four and a half years, that junction box had failed. Anytime you can keep electrical components out of direct weather exposure, do it. If your panels are rack-mounted and you have clearance underneath, look for panels with the junction box on the underside.

The second thing: cable length and placement.
Don’t be afraid to leave extra slack in your solar cables. If you need to remove or replace a panel down the line, having an extra foot or two (or even three) makes life so much easier. A little planning here can save you from having to add extensions or rewire later.

Finally: hide your cable glands.
I recently installed a set of 120W RedArc panels and noticed how the previous installer had run the cable glands straight up through the roof, fully exposed. While it worked, there’s a better way. Whenever possible, keep your cable glands tucked underneath the panels. That way, they’re protected from the sun, rain, and snow—leaving your connections safe and extending their lifespan.

A clean, weather-protected solar setup not only looks better but ensures fewer headaches down the road. A little extra time during the install goes a long way toward keeping your van powered reliably for years to come.

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