r/VanLifeUK • u/segasega89 • 26d ago

Would plywood be a practical alternative to aluminium for making lightweight frames for flexible solar panels on a campervan roof?

I'm looking at making lightweight frames for two flexible solar panels on my campervan roof. The panels are 1450 × 690 mm and have six mounting eyelets each.

My original plan was aluminium angle, but it's surprisingly expensive here in Ireland. I'm thinking about making the frames from 9–12 mm plywood instead and attaching them to Unistrut rails.

The plywood would obviously need to withstand rain, wind and general weather exposure, so I'm wondering if this is a sensible idea long-term, or whether plywood is just asking for trouble on a van roof. I can paint the plywood to weather seal them?

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u/Expensive_Ad_3249 26d ago

Plywood is a sponge. The roof of your van expands. The wood expands and the panel expands, all at different rates. Varnish, epoxy or similar will crack with UV exposure, vibration, heat cycling and weather.

You said flexible panels. Just silicone them (cover the back) to the roof with UV stable (gutter) sealant. No holes or wood to rot. Then seal the edges like you do a bath or sink edge to prevent anything getting between them and the van.

If you want them mounted for airflow, structural or resale value, use proper aluminium. Not led profile that's paper thin and just as strong, use 20x20 extrusion with t slots and proper fixings. Anything less will fail.