Recreational Vans

Rigid solar panels

Rigid panels explained and why they excel on the road

Rigid solar panels are framed modules built with tempered glass over silicon cells, sealed with an encapsulant and a weatherproof backsheet. That construction creates a stable surface that resists heat, wind, and road vibration better than most flexible options. On vehicles, the air gap beneath a rigid panel helps cooling, which improves real world efficiency during summer travel. Typical mobile arrays range from 200 to 600 watts, sized to match battery capacity, climate, and daily loads like refrigeration and fans. When shade hits part of a module, bypass diodes help reduce losses so the rest of the panel can keep producing.

Efficiency and cell types

Most van builds use monocrystalline rigid panels because they offer higher efficiency, often in the 19 to 23 percent range. Half cut cell designs improve shade tolerance and reduce resistive losses. PERC technology can boost output in low sun, which helps during shoulder seasons. While bifacial modules exist, the roof surface rarely provides enough reflected light to justify them on a van. For identical roof area, a quality mono rigid panel usually delivers the most wattage.

Durability, wind, and snow load

Framed modules are tested to international standards for mechanical loading, hail impact, and safety. Published ratings often show wind loads around 2400 pascals and snow loads up to 5400 pascals, which translates to strong resistance against highway wind and storms. The aluminum frame protects edges from knocks during travel and makes for secure mounting. On a vehicle, dynamic loads matter as much as static ratings, so a solid rack, correct hardware, and proper spacing are key to long life.

Mounting, wiring, and system design for mobile rigs

Mounting must balance strength, roof integrity, and serviceability. Low profile brackets reduce wind noise while maintaining an air gap for cooling. Many builders fasten to factory roof rails or a dedicated rack to avoid unnecessary penetrations. If roof penetrations are required, every hole needs proper sealing with compatible adhesives and mechanical fasteners. Cable entry glands should be UV stable and watertight, and all exterior wiring should be supported with strain relief to prevent chafe.

Roof layouts and tilt options

Panel placement should avoid shading from roof fans, antennas, and cargo. Wide, shallow arrays often outperform a single tall column because shadows move across the roof during the day. Tilt brackets can increase harvest when parked in winter, but fixed low profile mounts are simpler and safer for travel. If you use tilt occasionally, lock the panels flat before driving and verify clearances for tree limbs and parking garages. Leave room for access to clean glass and tighten hardware.

Controllers, wiring, and safety

An MPPT controller is preferred on vehicle systems because it optimizes voltage for changing temperatures and partial shade. Keep voltage drop under approximately 3 percent on the longest runs by selecting the right wire gauge and route length. Series connections reduce current and wire size but can suffer more under shade; parallel wiring keeps each panel independent but requires fusing for each branch. Use UV rated cable, MC4 connectors assembled to spec, and proper overcurrent protection near the battery. Good system design includes a master disconnect, labeling, and tidy routing that can be inspected later.

When rigid panels beat flexible film

Rigid modules have a lower cost per watt, better heat dissipation, and longer service life than most flexible panels. The glass surface cleans easily and resists UV degradation, while the frame keeps the module flat over time. Flexible film makes sense for rare curved surfaces or short term use, but on flat vehicle roofs, rigid panels usually deliver more energy across seasons and years. Their predictable performance simplifies planning your battery size and daily power budget.

Cost, performance, and lifespan tradeoffs

Expect a quality rigid module to hold output well beyond the first few years, with far slower degradation than thin laminates. Even with mobile vibration, a properly mounted rigid array can run for many seasons without significant loss. Flexible panels save weight but can run hotter against the roof skin, which reduces output during summer and accelerates wear. For most vans, choosing rigid modules results in better efficiency, longer lifespan, and fewer replacements over time.

Choosing the right array size starts with an energy audit. List your daily loads like refrigerator, lights, water pump, laptops, induction cooktop, and air conditioning assist. Add weather context because winter sun is weaker and summer heat raises temperature on the roof. Match the solar array to a battery bank sized for your camping style, then select an MPPT controller that can handle the total input voltage and current with headroom. Clean glass, secure wiring, and periodic hardware checks will keep the system performing at its best.

A professionally integrated system protects your roof, maintains warranty paths, and ensures every component is matched for the road. In Fayetteville Arkansas, OZK Customs designs and installs rigid solar packages that work with roof racks, fans, and vents while preserving service access. Our teams test harvest, verify charging curves, and deliver a walkthrough so you know how the system behaves in sun, clouds, and partial shade.

Bold move to better power If you want quiet energy for camp, reliable charging during travel days, and less generator time, a rigid array is the proven path. We build systems around real usage, from weekend trips to multi month routes, and tune gear for your climate and storage goals. Tell us how you live on the road and we will translate that into watt hours that match.

Your rig deserves a solar system that is tidy, quiet, and dependable. Tap below to start a conversation with our build team. We will recommend the right rigid modules, the best controller for your layout, and an installation plan that respects your roof and your time.

What we do OZK Customs builds custom vans and overland upfits with integrated power systems, solar arrays, ventilation, storage, and interiors that reflect how you travel. From complete custom builds to targeted upgrades, our Fayetteville Arkansas shop delivers reliable off grid capability and a smooth handoff at Adventure Point. Fill out the form and let us map your solar and power plan.