Overland Vehicles
A solar array for overland rigs turns sunlight into daily miles of independence. The right setup begins with a power audit, not a parts list. List every device, note watts or amps, and estimate hours used per day. Convert to watt hours so panel output and battery capacity speak the same language. This demand number guides panel area, controller size, and battery bank.
Panel output is limited by roof area and sun hours. Flat roof panels rarely hit their nameplate rating because of heat, dust, and off angle sun. In many parts of North America, planning for four to six peak sun hours in summer and two to three in winter is realistic. Multiply panel wattage by expected sun hours, then reduce by system losses to estimate daily harvest. A conservative plan prevents dead batteries after a few cloudy days.
Modern arrays use MPPT charge controllers because they track voltage to harvest more energy, especially in cold mornings and partial shade. Series wiring raises voltage for efficient MPPT input, while parallel wiring keeps voltage lower and can limit the effect of shading on one panel. Mixed or hybrid layouts are possible, but every choice affects wire gauge, fusing, and controller selection. Keep wiring short and sized for safe current with minimal voltage drop.
Lithium iron phosphate batteries pair well with solar because they accept high charge rates and provide deep usable capacity without sag. A battery monitor or smart shunt gives a true state of charge instead of guessing from voltage alone. Combine solar with alternator charging through a DC to DC charger, and use shore power occasionally to recover from long stretches of poor weather. Redundant inputs make a small array feel bigger.
Thermal management matters. Roof panels get hot which lowers output, so airflow under panels is helpful. Cleaning dust and pollen can reclaim double digit percentage points of lost production. Secure mounts with proper sealing protect the roof while bracing against trail vibration. Installations must survive real world conditions, not just a parking lot test.
Start with daily watt hours, then choose a target number of days of autonomy. Two days is common for active travel. Multiply your daily need by that number to size the battery bank’s usable capacity, then pick a battery configuration that fits your space and weight budget. From there, choose panels and an MPPT controller that can routinely replace your average daily use under expected sun.
Series stringing is efficient for MPPT and long wire runs, but shade on one panel can limit the whole string. Parallel wiring keeps each panel independent, but requires heavier cabling and larger fuses. On a roof with vents and racks that cause partial shade, a split approach with two short series strings in parallel can balance efficiency and resilience.
Every positive run needs proper fusing or breakers near the source. Use gland fittings or purpose built cable entries for clean, sealed penetrations. Strain relief, abrasion protection, and clear labeling prevent mystery faults a year later. A tidy system is easier to troubleshoot and safer on the trail.
Static specs do not capture the story of cloud cover, tree shade at camp, and dust from dirt roads. Design for variability. If you depend on a large fridge, a cabin fan, or climate control, give yourself margin. Panels on a roof rack may sit behind light bars or cargo boxes, so plan around shadows. If your travel includes winter, tilt brackets can improve shoulder season output when the sun sits low.
Battery chemistry shapes your experience. Lithium iron phosphate shines for weight, cycle life, and voltage stability. It does best with a battery management system that supports low temperature charge protection. In cold climates, look for internal heaters or mount batteries in a temperate cabin space. Lead acid variants work, but they are heavier and have less usable capacity. If you choose them, oversize accordingly.
Monitoring closes the loop. A shunt based monitor reports true current in and out, while Bluetooth apps from controllers and chargers add insight into daily harvest. Data lets you adapt. Park with the roof facing the sun, clean panels when output starts to sag, and shift heavy loads to midday when solar production peaks.
Use brackets and rails that spread loads and preserve roof integrity. Allow airflow under panels for cooler operation. Stainless fasteners and proper washers prevent corrosion. Seal every hole with products rated for the roof material, and revisit after the first thousand miles to retorque as needed.
Short runs, correct gauge, and marine grade copper deliver less voltage drop and more usable energy. Color coded heat shrink, labeled circuits, and service loops make future maintenance straightforward. Keep high current paths away from sharp edges and heat sources, and secure with padded clamps.
A DC to DC charger makes alternator charging predictable even with smart alternators. A small shore charger can recover during a layover. With three inputs, you can keep the array modest and still meet demanding loads, especially in forested regions or winter travel.
When you are ready to turn a plan into a clean, trail ready install, professional integration saves time and prevents headaches. Our team builds systems that pair roof arrays with the right controller, battery bank, and DC to DC charging, then validates everything with load testing and a full walkthrough. Explore our overland rigs to see how reliable power supports real travel. If your vision includes bespoke racks, interior layouts, and tuned electrical, our custom overland upfit service brings it all together under one roof. New to our shop and curious about our approach. Learn more at why choose OZK Customs.
At the end of every project we hand off a system you understand, with labeled circuits, tidy cable runs, and a charging plan that fits how you travel. Tell us your route and season, we will size the solar array for overland rigs that keeps your food cold and your lights on day after day.
Fill out the form and we will map your energy needs, model panel output for your region, and design a system that simply works.
Ready for dependable off grid power with zero guesswork. Our team designs, integrates, and tests full solar and battery systems that survive washboard and weather. Tell us how you travel, we will build the right solution and hand you the keys with a full walkthrough. Start your custom overland upfit today.
ADDRESS:
6159 E Huntsville Rd, Fayetteville, AR 72701
PHONE:
(479) 326-9200
EMAIL:
info@ozkvans.com