Part of our plan includes some rooftop storage and solar. With some deadlines looming for a few camping trips, I squeezed out the time to make some progress in that regard and we now have our 768 Watts of solar on the roof and converting energy for us. We had the rig in Snowmass a couple of weeks ago and it worked great... previously, we had to start the engine every few days to recharge.
As with so much of this truck, we're using materials we have. That grill bar, for example, was well pipe we pulled. The cage on top, supporting the solar and providing storage for paddleboards or other other things, was formerly a bunch of extra wire containers we had at the factory. Here are some pics:
So, between the wire cage and the frame it's quite sturdy but is fairly light. I welded up the frame and positioned it on the roof, then tack welded the 4x8-inch tabs while up on the roof (to get the slope angle right). I took the thing down, finished welding, installed the panels, and put it back up there. The final attachment relies mostly on Sika 252 with a couple of 1/4-inch lags in each plate, primarily to hold it while the SikaFlex cured. Before doing this, I did grind through the paint to make sure it's bonded to the aluminum itself.
Inside the rig, there's a Midnite Solar charge controller. Love that thing!
I also added a spare tire mount, positioned off-center to allow the MaxxAir vent on the other side.
At this point, it looks a bit funny with the cage all alone up there. The next steps include the "door" on the back of the cage, pipe rails down each side (allowing space between the rails and the cage for kayaks on edge, if we want), and a front roof rack over the cab (which will come up over the spare tire and raise any branches slightly above the side rails and solar panels).
Since installing this, it's gone from AZ to Snowmass and back, then from AZ to Austin and back. The wind gusts while driving to Austin confirmed it's definitely not coming off.