Protect Your Boat Deck: The Best Way to Install Walk-On Solar Panels

If you’ve ever installed walk-on solar panels directly on your boat deck, you might have noticed how much heat they can generate, especially darker panels. When I recently replaced the Solara walk-on solar panels on my Nordic Tug 37 with our new 325 Watt walk-on panels, I discovered that the heat from the black panels had significantly damaged the gelcoat underneath.

There were small, circular cracks in the gelcoat, about half an inch in diameter, confirming the need for a better mounting solution. This experience proved that our new walk-on solar panel mounting system is the right way to do a professional, long-lasting installation.

Why You Shouldn’t Mount Solar Panels Directly on Your Deck

Solar panels, especially black ones, can trap and transfer a lot of heat to the surface beneath them. Over time, this heat can lead to:

• Cracked or bubbled gelcoat

• Reduced solar efficiency from overheating

• Expensive repairs to the deck surface

The key is allowing airflow between your deck and the solar panel.

Our Recommended Mounting Method: Twin Wall Polycarbonate Base

We recommend placing a 4mm or 6mm twin wall polycarbonate sheet between your boat deck and the solar panel. This strong, fluted material provides a cushion of air that keeps the deck cool and prevents heat buildup under the panel.

Here’s how it works:

1. Place the twin wall polycarbonate under the panel.

2. Use an aluminum “J” extrusion to secure both the polycarbonate and the solar panel.

3. Attach the back of the “J” to the deck using 1-inch wide VHB (Very High Bond) tape.

This simple setup:
✅ Allows airflow to cool the panel and deck
✅ Protects the gelcoat from cracking
✅ Keeps your system low-profile at just 10mm (5/16 inch)
✅ Increases solar efficiency through cooler operating temperatures

Real-World Test on My Nordic Tug

I’ve installed this exact system on my Nordic Tug 37, and the difference is remarkable. The panels stay cooler, the deck is protected, and overall solar performance has improved.

You can watch the full installation in my video demonstration here:

Key Takeaways

• Always use a ventilated mounting system for walk-on solar panels.

• Twin wall polycarbonate prevents gelcoat damage and heat transfer.

• The VHB + aluminum J-mount system provides a strong, clean, and low-profile installation.

Recommended Product

✅ All Walkable Panels (with part numbers ending with "P") come with J brackets and properly sized polycarbonate included.

If you’re upgrading or replacing marine solar panels, explore our Semi Rigid Walkable Marine Solar Panels — built with SunPower A+ Grade cells (24.4% efficiency) and designed for marine-grade durability.