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21st Aug 2021, 04:32 PM #16Diamond Member
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Light Channel.jpg
The light channel showing the general arrangement with the centre join of the two sections
light channel flange.jpg
The centre flange joint. This will need removing to fit a one piece strengthening insert, which I am considering. The insert would be riveted to the present structure.
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21st Aug 2021, 06:27 PM #17Most Valued Member
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Yes, pity the manufacturer used that construction method - basically creating a complete weak join line right trough yhe roof.
I probably wouldn’t bother putting a one piece beam in there, and would just jack it into position (maybe slightly above where you want it to end up) then fit a 2mm?? doubler on the bottom with bolts in interference holes or some proper structural fasteners (which hollow aluminum rivets aren’t).
Steve
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21st Aug 2021, 07:24 PM #18Diamond Member
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That would certainly be easier than my idea of removing the light channel sections, cutting out the internal flange joint and fabricating a "U" shaped insert, faithfully duplicating all the cutouts, fitting it to the present light channel sections and then riveting it all back together again. My only concern is that the light channel is aluminium as far as I am aware, and probably not anything particularly strong either. I wonder if it would be strong enough. I might get in touch with the manufacturers to see what it is made from. It measures 1.9 mm± with powder coat on both sides, so probably only 1.5 mm BMT.
Rob
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21st Aug 2021, 11:25 PM #19Most Valued Member
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Just looked at the photos again and rather than just a flat doubler across the bottom a longer angle piece along the lower corners would probably be better.
Reason being is the middle bit at the join is only about 30mm each side of the join - with 1.5mm original material I think it would be better to get a bit more material either side of the join.
You could still do a doubler in between the angles on that lower face if you wanted. Nicer still would be a bent piece that went across the bottom ad up each side - cut to the same shape as the existing cutouts.
Steve
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22nd Aug 2021, 12:24 AM #20Diamond Member
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G'day Simon,
I missed this post of yours earlier thank you for the good wishes for a positive outcome, I'm hoping for it too! Yes the 600 series Victron BMS has most of the features of the later variants, but is not bluetooth enabled, so no ability to monitor on Victrons' Ap. The Ap is definitely more user friendly, but the info is there on our older model, just not so easily accessible. I am pretty sure that most of our problems have been due to the degraded panels, but made worse by the roof failure. With the droop of the roof and the bonded on solar panels, meant that any moisture from a rain shower or even the evening dew would pool and attract any dust to make a thin layer of mud on the panels. I don't carry a long ladder when travelling only a 2 step folding stepladder, and that is not tall enough to reach the roof. We also generally travel the outback, so water is precious, and the opportunity to hose down the panels is infrequent. Even if I get to clean them, it usually only takes a couple of days to get back to square 1. Perhaps I need to carry a taller ladder, but I can't take everything.
I hope that with having a lot of excess generating capacity, and having it distributed so that we can have the ute in the sun for power, without making ourselves uncomfortable in the process, will put an end to these hassles we have had, and it would be really nice to be able to leave the Honda EU20i at home. It would save a fair bit of weight, and petrol smell in the storage compartment, and of course the irritation for those not enthralled with the hummin Honda.
The manufacturers of our van are excellent people, and while I do not expect a new roof, they give freely of their expertise and I can run my ideas past them for any repair proposals I may have. I'm sure that it will work out in the end and I will certainly report in with any news at the work progresses.
Rob
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22nd Aug 2021, 12:39 AM #21Diamond Member
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Yes Steve, I was originally thinking of a U Shaped piece fitted internally, with the cutouts duplicated, but much easier to fit to the outside, as I think you are suggesting, just need a bit more care with the cutouts to make them tickety boo. Thanks for all your suggestions, I will run them past the manufacturers Service Support, they are most helpful and a good sounding board for any ideas. Cheers,
Rob.
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