New Solar Panel Mounting Brackets

Hi,

I've got an older solar panel array, with 180 watt panels. I want to upgrade to new panels int he 400 watt range. Here's the problem:

I have a metal roof, and I had the solar installed at the same time as the roof, so the solar panel and roofing crew worked together, and it went really well. Now, 20 years later, the newest solar panels are in the 400 watt range, but are slightly bigger than the old panels, so the panel brackets don't match the new panels. I don't want to punch any new holes in my metal roof.

The solar companies I've spoken with tell me they can't modify the old brackets to take the new panels. It's hard to believe that with the MILLIONS of old panels out there, thee hasn't been a work-around to mount the new, larger panels.

Has anyone done this? I'd love to more than double my output, as that would basically cover my electric needs, and I could put a wall mounted storage battery to cover me during my (expected) outage after hurricanes.

Thanks in advance for your input and wisdom.

Cara,

I expect their response is based on two factors: liability and cost.  The cost of fabrication for a small number of anything is high per unit all in for set up testing and waste.  Doing 1 job may simply not be worth it.  Liability has several factors they must consider.  If it is not a tested or certified part they are not insured if it fails and if they intellectual property belongs to someone else (or they are under a dealer agreement) then something like this could cost them their relationship with the manufacturer.  Hard to tell which.

Can you get a picture of the brackets and post it here?  Also a company name or product number might help do some research.  Before you go down that rabbit hole however ask who will do the work?  Will they stand behind the work?  Are you willing to take the risks if the modifications don't work long term?

Post a picture if your able.  Lot's of handy people here can give you an idea of what is possible.

Thanks, Jack. You've made some good points, but it doesn't seem like mounting brackets should be some proprietary maze. I'll look up the manufacturer, but I don't think I can get pictures of the brackets, since I'm past the age of getting up ladders to the roof. Damned blood thinners.... I should call some of the installers back and see if anything has changed. It's been about a year.

By the way, I'm Gary, and just happened to sign in on Cara's account.

What type of metal roof is it? If it is a standing seam of any sort there may well be clamps that can fasten things to the ribs without more holes..

If not, you could possibly use a system of rails attached to the existing brackets, and then mount new panels on the rails.. assuming the brackets can handle the weight. It's not going to be easy to diy this without roof access, or cheap to have someone do it for you, though.

If it is through-fastened roofing, that won't work.. but there would be a lot of existing holes for screws that are generally supposed to be checked and tightened at regular intervals, as they will tend to loosen and leak over time; I wouldn't fret about a few more holes with this sort of roof!


I doubt there is a ready-built adapter meant to solve this issue, as panels have never standardized enough in size to make this look like a really compelling business opportunity, especially with all variety in installations..

D Nikolls wrote:What type of metal roof is it? If it is a standing seam of any sort there may well be clamps that can fasten things to the ribs without more holes..

I doubt there is a ready-built adapter meant to solve this issue, as panels have never standardized enough in size to make this look like a really compelling business opportunity, especially with all variety in installations..

Thanks for the reply. It's a 5 V Crimp roof. Trusses were sistered, and the brackets sunk into the trusses. I doubt there would be enough room. to sink new brackets and meet code, and the city is always trolling for work without permits. I talked to a solar install company, and confirmed that there are no adapters. I brought up the idea of rails, as you mentioned, and, no, there's no system currently. Here in S. Florida, in order to get approval for something like this, takes tens of thousands of dollars, and LOTS of time. But considering how many old solar panels like mine are out there, it seems like it would be worth it. Not my skill set, unfortunately.

Your upgrade could take a different path.....leave the old panels and add 400W panels near the ground. Do you have a back porch? One method would entail using a few new panels as a cover for a patio or porch.  Have it framed in a manner that partially hides the power generating portion of the addition. Or create a shade garden that could grow kale or collards in the subtropical climate.  No roof work needed if you can pull it off.

We have, unfortunately, no room for ground panels and many trees around, so this is an excellent suggestion but not in our case.