BIGGEST SOLAR ARRAY EVER!!! – Expedition Truck Camper Build!

This is quite possibly the BIGGEST SOLAR ARRAY I've ever seen on any truck camper! 800 Watts of solar goodness.

Making a truck camper functional off grid requires POWER! We love SOLAR as it is renewable and silent. But getting a functional solar setup means you need A LOT of solar.

Here’s the parts we used:

Renogy 160W Flexible Solar Panels (check out their newest 175W panels). Best warranty available 25 years. We used their MC4 solar panel extension cables in 10 AWG to connect the panels to the junction block. Stainless #10 screws in all 6 solar panel eyelets with Butyl tape squares under each eyelet where screw penetrates the roof. Dicor 501 covering all screws and completely around the entire parameter of the solar panel (avoid water and air getting under the panel). This method is great for TPO or EPDM roofs (rubber roofs). For metal or fiberglass the 3M VHB tape with Dicor would work for no holes in the roof.

Blue Sea DualBus Plus 150A – junction block to connect solar panel wiring. Using marine ¼” ring terminals 10 gauge heat shrink connectors. Buy a good crimper compatible for heat shrink fittings. TEMCo 6 gauge welding wire to connect junction block to the 70 AMP Bussmann breaker and Victron 50/100 solar charge controller. You’ll also need 6 AWG marine wire lugs (1/4”) – I used SELTERM tinned copper studs. And TEMCO lug crimber tool.

Victron MPPT Control (remote screen for monitoring) and Victron VE direct cable to connect monitor to charge controller.

Solar charge controller connected to 70 AMP Bussmann breaker via 6 AWG TEMCo wire. Then connected to bus bar. Which was connected to Blue Sea battery switch. Which was connect to the battery via 4/0 gauge TEMCo wiring.

Victron Battery Monitor kit for monitoring battery charge.

Battle Born 100amp Lithium Batteries.

That’s the solar wiring overview of parts needed. You’ll also need lots of small things like screws, zip ties, cable management, sleeving… You’ll want to draw out your entire solar layout. This will help you determine wiring lengths, then you can figure out proper wiring gauges depending on your loads. Lots to learn!

Parts Sources: Amazon & Powerwerx (for breakers, ring terminals)

Hope that helps get you started!

#expeditionoverland #truckcamper #solarinstall

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