Foamie solar panel cover

[Ratkity]

My 85watt solar panel is here! It's a good thing I waited before cutting anything until it arrived as I had written down the wrong measurements. I had looked at so many panels, there's no wonder I got the wrong numbers down.

So why a cover? This is for only when driving. I have a 2009 Reverse TD from Little Guy and the solar panel is going on the front slope of the TD. This is an area where road debris could possibly hit the panel and panels don't do well with dings. It can handle 50 mph hail, but probably not my warp speed down the highway.

Since helping eagle with the numero uno Foamie TD, I know how strong, yet flexible cloth or canvas covered foam can be.

[Ratkity]

Materials:

Titebond III

Pink 1" foam board (my box store didn't have the blue) - Worked out great because this is 24" x 8 ft and $9.38



Hot Chili Pepper cloth


Buckles and straps



Oh! and the solar panel - 85 watts 45" x 20" from ul solar

[Ratkity]

So um, despite being very scientific and being able to draw a straight line, apparently, no matter what tool I use, I can't cut straight! LOL.

No worries. I have a little hand sander that will smooth out the imperfections, and as eagle and I found out, the cloth will hide a myriad of mistakes!

Note the blue painter's tape. My auntie has stock in 3M and I have gotten a free roll of that stuff for the past 6-7 yrs. I use it for lots of things!



So, it's in the basement, drying - slowly drying.

I was worried the combo of pink background and titebond would discolor my fabulous pepper fabric, so rummaged around in my cloth scraps and found some white cloth to use as an initial covering. I also found some old soft upholstery fabric I can cover the inside of the foam cover with (the rose colored stuff in the upper panel).

[swampjeep]

cool

what glue are you using to join the foam to foam (sides to main cover)

[eaglesdare]

yes i do like that new fabric. can't wait to see this complete. and loving all the pics!

[Ratkity]

Using Titebond III - if I'm not happy with it, I have the old GG standby.

Hugs,
Ratkity

[GPW]

That's going to be One DELUXE Solar cover !!!
If the T3 ever dries ... inside that non porous foam ... tried it , never worked for me ... the outside was dry , buy weeks later the inside still had wet glue ... the reason I used GG now for foam to foam

[Ratkity]

That's going to be One DELUXE Solar cover !!!
If the T3 ever dries ... inside that non porous foam ... tried it , never worked for me ... the outside was dry , buy weeks later the inside still had wet glue ... the reason I used GG now for foam to foam

GPW, the T3 was taking too long to dry, so I switched to some multi-purpose Gorilla Glue. It is setting now.

I *cough* *choke* sanded the top and edges *bats at flying pink dust*.

I was going to cut the white duck cloth I had hanging around and didn't have to - it was like it was MADE for this application. I think that stuff has been hanging around in my scrap box for 15 yrs. There are some spots on it and a run.. yay for thriftiness!

*stops and blows a few pink boogies*

Hugs,
Ratkity

[GPW]

A simple dust mask might be a really Good idea when sanding this stuff...

[eaglesdare]

A simple dust mask might be a really Good idea when sanding this stuff...

especially indoors

[Ratkity]

A simple dust mask might be a really Good idea when sanding this stuff...

especially indoors

Yup, recommended. Bandana works in a pinch.

Hugs,
Ratkity

[Ratkity]

Rounded edges







First coat of glue




First cloth layer:




Bottom showing first cloth layer:



Top showing first cloth layer:

[eaglesdare]

looking good. can't wait to see the finished product. don't forget vinegar is good for removing glue in the hair.

[Ratkity]

looking good. can't wait to see the finished product. don't forget vinegar is good for removing glue in the hair.

No upside down gluing on this panel! *phew*

Hugs,
Patricia

[Ratkity]

More progress!

This is my scrap upholstery cloth being fitted. It doesn't reach the sides, but that's ok since the duck cloth is there. There will be white showing on the long edges. It's a very soft and thick fabric, and I thought it would protect the solar panel from scratches from the foam or glue leftover inside the cover.



Fitting the pepper cloth:






Second gluing!! This was spread out in a fairly even coat of thick glue using a stiff foam roller (seen in one of the first picts). The small size of it was great for getting into corners and doing the edges.



Pepper cloth stretched tight over the glue!



Figure out the corners. Eagle had a time with corners on her doors, so I made sure I left a lot of room in the dimensions to allow for a bulky inside corner. I glued the corners down like wrapping paper.





Letting the glue dry: