CMPower Impact Resistant Walk-on Solar Panel Installation Guide

This manual is intended to provide the information needed to properly install the CMPower impact-resistant walk-on panel kit on van roof racks.

Background:

At high speeds, the air pressure between the van roof and the van rack may be elevated, and the air pressure above the solar panel may be reduced. Much like an airplane wing.  If the rack under the panel is not a solid material securely attached to the roof rack, the change in air pressure will tend to lift the panel off the rack.  Also, the edge of the panel facing the front of the van, which is exposed to the wind, may be lifted by the air flow.  Attaching the solar panel to only four corners is inadequate and may result in the loss of the panel.

As solar panels heat up in the sun, their performance is reduced because the solar cells become less efficient at higher temperatures.  In fact, a solar panel will lose up to 10% of its rated output for every 30 degrees F above 75 degrees F.

 The CMPower solar panel mounting system is designed to both secure the solar panel to the van rack and optimize panel performance by reducing the panel's operating temperature. Using alternative installation techniques may void the warranty.

Components included in the kit:

1. CMPower high-performance impact-resistant walk-on solar panel.
2. CMPower twin-wall polycarbonate underlayment sheet for strength and cooling.
3. “J” channel mounting extrusions to secure the panel and polycarbonate to the van rack.

Components not included in the kit:

1. Outdoor Very High Bond (VHB) 1-inch-wide double-sided tape.  We suggest a tape comparable to 3M 5952 VHB double-sided tape.  It is available online and at some hardware stores.  Each roll is 15.4 ft.  One roll is required for panels 100 watts or smaller, and a portion of a second roll will be required for panels larger than 100 watts.

2. Fasteners are required if the mounting brackets are to be bolted to the deck or roof rack. Silicone sealant. Rivnuts + matching bolts and Drop-in T-nuts if mounting directly to the rack crossbars through the deck panel slots.

Tools needed:

1. Measuring tape
2. Pencil or marking device
3. Electric drill if using fasteners for additional security. 
4. Volt meter.

Preparation for installation:

1. Test the Solar panel – Use a volt meter before beginning the installation to confirm the solar panel is operating properly. Expose the panel to the sun and place the meter probes on the positive and negative wires connected to the panel. When production is verified, proceed to step two. If not, contact Custom Marine Products.

2. Create a solid surface under the solar panel - If there are holes in the roof rack of significant size under where the panel will be mounted, we recommend covering the holes or attaching an aluminum plate securely to the roof rack to prevent the high-pressure air from lifting the solar panel assembly at high speeds. 

3. Pre-install VHB tape - VHB tape should be used in the center of the panel and the polycarbonate to prevent any lifting of the solar panel and the polycarbonate sheet when the vehicle is travelling at high speeds.  Place a 12-inch piece of VHB tape in the center of the panel back and the polycarbonate parallel to the long edge of the panels.  Peel back the protective tape covering (release liner) on one side of the tape and adhere the tape to the back of the panel and to the side of the polycarbonate facing the roof rack.  Leave the release liner on the other side of the tape until later in the installation process.

4. Pre-install VHB tape - If the panel is positioned such that the short edge of the panel is facing into the wind when the vehicle is in motion, install VHB tape in the center of the back of the solar panel along the outer leading edge.  Do the same for the polycarbonate sheet using the same technique as in step 2 above.  

5. Pre-layout and hole preparation - (If fasteners are to be used to fully secure the solar panel)

   • Assemble the CMPower solar panel kit by placing the solar panel over the polycarbonate and sliding on the J channels on each side.  Position the assembly on the van rack. Check fit.

   • Drill a proper-sized hole to accommodate the fastener through the solar panel, the polycarbonate, the J channel, and the van rack.  If the solar panel has grommets in the corners, use the grommet hole to position the drill so the bolt will go through the grommet.  If the panel does not have grommets, drill the hole in the place marked on the panel or 9/16ths in from each edge of the panel. Install rivnuts in the roof deck panel OR use T-nuts if holes align with the deck panel slots/crossbar channels.

6. Pre-install VHB tape on J channels - Apply 1” strips of VHB double-sided tape to the back surface of the J channel that will be against the roof rack.

• • Clean the J channel back with alcohol or an equivalent to ensure a tight bond. 

  • Pull off about a 4-inch section to the protective tape covering (release liner) and press the tape against the J channel.  The tape should be even with the outside of the J channel and will stick out past the J channel back a bit. Continue for the full length of the J channel. Repeat on the second J channel. Punch holes in tape.

Installation Instructions:

1. Position the solar panel assembly on the van rack.
   Assemble the CMPower solar panel kit by placing the solar panel over the polycarbonate and sliding it on the J channels on each side.  Position the assembly on the van rack, lining up all holes.

2. Draw a line along the edges of the J channel and mark each end position.

3. Install the first J channel mount.
   Clean the area on the rack that the tape will adhere to using alcohol or an equivalent solvent. Clean the areas for both J channels. Peel off the release liner from the VHB tape and carefully position the J channel mount on the roof rack using the markings from step 2.  Press firmly on the J channel to ensure a strong bond.

4. Slide the twin-wall polycarbonate into the J channel.
   Remove the release liner from the tape in the center of the polycarbonate panel and on the leading edge of the polycarbonate panel (if used). The tape will stick to the protruding VHB tape on the J channel, so slide it in at an angle and then lower it onto the van rack.

5. Slide in the solar panel between the top of the J channel and the polycarbonate.
   Remove the release liner from the tape in the center of the solar panel and on the leading edge of the panel (if used). Slide the solar panel in at an angle and then lower it onto the polycarbonate.

6. Install the second J channel mount.
   Peel back the release liner about 3 inches and fold so the liner is sticking out beyond the outside of the J channel. This will act as a pull tab. Slide the J channel onto the solar panel and polycarbonate. The VHB tape protruding beyond the back of the J will make this a bit tricky, so approach the panel with the J channel at an angle. Two people may be required for this step.
   Important: Allow about 1/8th of an inch between the panel and the inside of the J channel to accommodate panel expansion.
   
   With the J channel in place, pull the release liner tab carefully while holding the J channel in position. Once the release liner is fully removed, press hard on the J channel to secure the J channel to the rack.

7. Apply pressure to all areas where the VHB tape is used to firmly adhere it to the panel and the vehicle.

8. Install fasteners to each corner of the solar panel using the holes drilled in the preparation section. If the panel does not have grommets, use an appropriate size washer with the fastener. Applying a silicone sealant around the fastener to assure proper sealing is optional, but should be considered.  Secure each fastener.

Important Notes: 

VHB Application Tips:

• Clean surfaces with a 50:50 mix of isopropyl alcohol and water.
• Ensure surfaces are fully clean and dry. 
• Apply tape, then press firmly with a roller or by hand.
• 50% strength in 20 minutes, 90% after 24 hours, 100% after 72 hours. 

Maintenance:

Inspect all components regularly to ensure long-term safety and performance. Every 3–4 months, recheck the following: 

• VHB Tape Bonds: Verify that all adhesive joints remain secure and fully bonded. Look for any peeling, lifting, or signs of separation, especially at the channel edges or where exposed to heat and UV.
• Bolts and Fasteners: Confirm that all hardware is tight and torqued correctly. Retighten any loose bolts and apply thread locker if needed. 
• Panel Alignment: Ensure the solar panel and polycarbonate sheet remain flush and evenly supported within the J-channels. 

Warranty:

• The CMPower 5-year solar panel warranty is valid only if the panels are mounted on a van rack as specified in this document or mounted using another method pre-approved in writing by Custom Marine Products.
• The twin-wall polycarbonate sheet may be discarded if pre-approved in writing by Custom Marine Products. Smaller J-channel mounts that will accommodate only the solar panel will be necessary. These are available by special order. 

Disclaimer: By installing this product, the user assumes full responsibility for correct installation, maintenance, and use. Orion Van Gear and Custom Marine Products expressly disclaim all liability for any damage, injury, or loss resulting from improper installation, misuse, inadequate surface preparation, insufficient adhesion, or failure to follow instructions. Use of this system constitutes acceptance of these terms and a waiver of all claims against Orion Van Gear, Custom Marine Products, and their affiliates. It is the user’s responsibility to ensure secure adhesion and fastener integrity prior to operating the vehicle.