Roof Top Combiner Box

Another day, another hole in the van.

There's plenty of items on the roof that require wiring to come inside the van somehow:

1. Solar panels
2. Exterior lighting on the sides and rear of the van
3. Camera and power to the digital rear view mirror camera
4. Security cameras (maybe)
5. Starlink satellite internet antenna (maybe)
6. Cellular PEPLink antenna (maybe)

So instead of making six holes, let's make one larger one and use a roof top 'combiner box' with waterproof cable glands.

Some DIY their own box, but getting it low profile enough to fit underneath the rear most solar panel is difficult. The hole in the roof has to be in the rear corner on the driver side since that's where the electrical system will be installed.

Found that AMSolar makes a fantastic, UV proof box for this and bought one; just in time as a few months afterwards they closed up shop and they're no longer available. It has two bus bars internally that make combining multiple solar panel wiring within the box a breeze. "Future John" will appreciate that I decided to double the size of the hole through the bottom for better wire clearance in the event all 10 cable glands end up being used.

Then it's time to mask everything off again and create another hole in the roof.

Prime and paint the edges and wait for that to dry (and re-check weather forecast).

Some 3M VHB tape and more Sikaflex 221 adheres the box to the roof. And then the edges get a filet of Dicor lap sealant. I purposely positioned the box towards the middle of the van just a bit so that I didn't block the water channel that will run along that adjacent roof rib. Lots of dirt and debris would collect there otherwise with the box acting like a dam.

I neglected to get a picture with the cover on it, but it has a rubber gasket and 10 screws holding it on. Plus the whole box is sun and rain sheltered somewhat since the solar panel covers it.