Sliding Solar Panel Rack Systems by Orion Designs

KDE

New member
Ps.... do you want to know how much a "Socket Button Head Cap Screw: 5/16-18 x 0.625" weighs? 0.0167 lbs / 0.2672 oz / 75.75 gram. :smilewink:

nice work! devil is in the details!
 

Cheyenne

UK 2004 T1N 313CDi
Ps.... do you want to know how much a "Socket Button Head Cap Screw: 5/16-18 x 0.625" weighs? 0.0167 lbs / 0.2672 oz / 75.75 gram. :smilewink:

nice work! devil is in the details!
Hmmmm, not quite!

Methinks you have the decimal point in the wrong place...

0.0167 lbs / 0.2672 oz / 7.575 gram.

Keith.
 

OrioN

2008 2500 170" EXT
Hmmmm, not quite!

Methinks you have the decimal point in the wrong place...

0.0167 lbs / 0.2672 oz / 7.575 gram.

Keith.
:eek:

This may delay the product release date, while I do a thorough audit!! :frown:

Kidding aside, the BOM data shown in lbs is from an industry CAD library and correct. The other two, oz. and grams, I converted from Windows tool, and typo'd.


Annotation-2019-12-01-121839.jpg

Being in the UK, you may relate to the "Equals 0.02 Soccer Balls" in the image. :smilewink:
For some reason, I can't change that to something more relevant to me like "Piece of Sashimi"



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Boxster1971

2023 Sprinter 2500 144wb AWD
I noticed that the maximum array length is 3 inches less for the "Motor Kit" compared to the manual racks. Is this due to travel limits of the linear actuators or some other factor?
 

Boxster1971

2023 Sprinter 2500 144wb AWD
No locking mechanism for when it is extended. I could not see any reason why it was necessary.

Posting here helps others who may have questions and bump up the thread. :thumbup:

Some questions here may be candidates for the site`s FAQ.
Right - with the motor kit models the linear actuator would keep the sliding panels in place. On the manual models is there enough friction in the uni-bearing slides to keep the extended panels from moving in windy conditions?
 

OrioN

2008 2500 170" EXT
I noticed that the maximum array length is 3 inches less for the "Motor Kit" compared to the manual racks. Is this due to travel limits of the linear actuators or some other factor?
Consider a 48xx series....

The Leg Rails and PV Slider Bearing Rails length is 50". By design, I made the Linear Bearing's extension 50" + 3" or 53". The additional 3" is shadow mitigation.

The Actuator has a 48" extension.

If I were to spec the Actuator to have a 50"-53" extension, the Front & Rear Actuator Brackets' footprint would be much prouder, and less optimal when considering one of the principle design intent of these systems is compactness and efficient footprints.

Secondly, if you look at the attached drawings, you will see that if one wants to they could put a larger length array. BUT, it is not recommended for the sole reason of minimizing shading from the upper array or cargo rack. One would need to 'track' their vehicle towards the sun to mitigate.

View attachment SR2S-4800-E-E-Top & Side View.pdf

View attachment SR1R-4848-E-E-Top & Side View.pdf

All series drawings will be posted on the site shortly....





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OrioN

2008 2500 170" EXT
Right - with the motor kit models the linear actuator would keep the sliding panels in place. On the manual models is there enough friction in the uni-bearing slides to keep the extended panels from moving in windy conditions?
Correct, the bearing's moment of inertia is higher than the wind's horizontal force.
 

Boxster1971

2023 Sprinter 2500 144wb AWD
. . . Secondly, if you look at the attached drawings, you will see that if one wants to they could put a larger length array. BUT, it is not recommended for the sole reason of minimizing shading from the upper array or cargo rack. One would need to 'track' their vehicle towards the sun to mitigate. . .
Yes - minimizing shading is critical. For my next 144" Sprinter looked at using a RoamBuilt Shadow Rack and just attach solar panels on top of rack. [See attached photo of Shadow rack.] But I have little use for a large roof rack. The SureShade on the ShadowRack is an appealing solution for an awning that can handle more wind than a typical RV awning.
https://www.sureshade.com/sureshade-debuts-new-sureshade-rv-segment-at-rvx/

Using one of your Sliding Solar Panel Rack Systems I could get max solar and a small awning over the side door in one compact package.
 

Attachments

Boxster1971

2023 Sprinter 2500 144wb AWD
SEO time....


...say hello to my leetol friend.

Or, for this season, my 'L'f on a shelf'.

https://oriondesigns.ca/our-products/

https://oriondesigns.ca/
I have some Combi-Cam locks on my van and they are a lot better than the keyed locks. This end bracket and combi-cam lock combination is a great feature of your design. Integrating a locking device was often a weak point in many of the DIY sliding and tilting solar racks I've seen.
 

OrioN

2008 2500 170" EXT
Do you think a cover might be needed on the Combi-Cam? Like this one from FJM Security Products? Mine are on the inside and not exposed to rain, snow or dust.
They are included with the kits.

FJM doesn't have 3D CAD models for them, so they are not on the renders.

In fact, they didn't have their Combi in 3D CAD when I inquired. So I created it, then gave them the model. As appreciation, they gave the products I ordered for prototypes for free. :clapping:


SR1S-48xx-M-TX50-R-L-crop-810-90.jpg
 
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Boxster1971

2023 Sprinter 2500 144wb AWD
They are included with the kits.

FJM doesn't have 3D CAD models for them, so they are not on the renders.

In fact, they didn't have their Combi in 3D CAD when I inquired. So I created it, then gave them the model. As appreciation, they gave the products I ordered for prototypes for free. :clapping:
FANTASTIC!!:thumbup:
 

jostalli

Member
Orion, great job! I think a lot of us have wanted to build this exact product. We have clients who have asked for similar solutions but we never wanted to commit to building something that we could not fully test.
 

Goofy foot

sliding left...
Orion, do you have an option for mounting to T1N’s ? Renderings all seem to be for NCV3’s. Or are they not Sprinter specific, therefore we have to facilitate your racks to our vans ?
 

Boxster1971

2023 Sprinter 2500 144wb AWD
This is epic.
I agree!

Orion, great job! I think a lot of us have wanted to build this exact product. We have clients who have asked for similar solutions but we never wanted to commit to building something that we could not fully test.
Yes - I've looked at many sliding solar panel systems on YouTube and other forums. Most were DIY projects of varying quality. I found two companies selling kits:

Dunn & Watson in Australia, who sell some of the parts on Amazon. But the shipping costs are crazy. They only have kits for 80 or 100 Watt panels, more suited for off-road 4x4s.
https://trailerpartsdirect.com.au/s.../solar-panels/100-watt-slide-out-solar-panel/

Another company, Prepper Solar Roof Racks, in Texas makes roof racks for 4x4s, but they don't look suitable for vans.
https://www.prepperracks.us/

The best DIY project was by Everlanders at this video link.
https://youtu.be/cM5s4F-7AOk

Very well done with air power on a Ford F550 based Expedition vehicle. Jason got a lot of great comments and many who wanted him to sell kits, but he wasn't interested.

Another interesting and epic project was by "Beginning from this Morning" placing 3500 Watts of solar on a 1964 converted GM bus.
https://youtu.be/UhvWJZjqRJs

Both of these DIY projects, like many others, used ball bearing drawer slides. Everlanders washed out all the lube from the slides so they would not collect dirt. But they still needed to clean them with a pressure washer regularly. Using Unibearings as Orion is doing should work much better.
 

OrioN

2008 2500 170" EXT
Orion, do you have an option for mounting to T1N’s ? Renderings all seem to be for NCV3’s. Or are they not Sprinter specific, therefore we have to facilitate your racks to our vans ?
At this time I do not offer a 'Mounting Kit' to mount to the T1N gutter. I cannot say if or when there would be, as T1N's are now out of production and 14 years old.

However, any of my Series systems can most certainly be mounted with a couple of caveats. It is imperative that you use the kit's Uni-Legs, and mounted to t-slotted roof-rails. This gives you the ability to get and keep the system not only rigid but more importantly square and leg rails parallel, otherwise, the slider bearing, which has 0.5mm tolerance/gap, will bind or jam.

That said, if you look at my Transit Roof-Rail Kit offering, if the T1N roof's angle is ~5 deg, these will work. If not, make some custom L-Brackets with the appropriate bend to match the T1N's roof angle.

https://oriondesigns.ca/our-products/roof-rail-kits/roof-rail-kits-ford-tx50/

RR-TX50-3x-N-Z-960x540-90.jpg
 
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GeorgeRa

2013 Sprinter DIY 144WB, Portland OR
I agree!



Yes - I've looked at many sliding solar panel systems on YouTube and other forums. Most were DIY projects of varying quality. I found two companies selling kits:

Dunn & Watson in Australia, who sell some of the parts on Amazon. But the shipping costs are crazy. They only have kits for 80 or 100 Watt panels, more suited for off-road 4x4s.
https://trailerpartsdirect.com.au/s.../solar-panels/100-watt-slide-out-solar-panel/

Another company, Prepper Solar Roof Racks, in Texas makes roof racks for 4x4s, but they don't look suitable for vans.
https://www.prepperracks.us/

The best DIY project was by Everlanders at this video link.
https://youtu.be/cM5s4F-7AOk

Very well done with air power on a Ford F550 based Expedition vehicle. Jason got a lot of great comments and many who wanted him to sell kits, but he wasn't interested.

Another interesting and epic project was by "Beginning from this Morning" placing 3500 Watts of solar on a 1964 converted GM bus.
https://youtu.be/UhvWJZjqRJs

Both of these DIY projects, like many others, used ball bearing drawer slides. Everlanders washed out all the lube from the slides so they would not collect dirt. But they still needed to clean them with a pressure washer regularly. Using Unibearings as Orion is doing should work much better.
I wouldn't use ball bearing sliders in this application. Likely a headache.
 

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