Van power systems are the hidden base that makes modern van life work. Get your power system right, and you'll enjoy steady power for all your gear, from LED lights to laptops to fridges. Get it wrong, and you'll find yourself constantly managing power, dealing with dead batteries, and missing out on the adventures you planned.
After nearly a decade of planning and putting in van electrical systems in Colorado, we've learned what works well in real-world use and what leaves van lifers stranded with dead batteries. This complete guide explains solar power van conversion systems, battery types, and how to design an electrical system that actually meets your needs.
Understanding Van Electrical System Fundamentals
The Four Essential Components
Every van electrical system consists of four key elements that must work together seamlessly:
Power Source: Solar panels, alternator charging, and shore power input. Energy Storage: Battery banks that store power for later use. Power Control: Charge controllers, monitoring systems, and safety gear. Power Flow: Inverters, DC distribution, and electrical outlets.
DC vs. AC Power in Van Applications
12V DC Systems: Most van gear runs on 12V DC power straight from your battery bank. This covers LED lights, fans, water pumps, and many fridges. DC systems are efficient because they cut out conversion losses.
120V AC Systems: Standard home gear needs 120V AC power, which means using an inverter to change your 12V battery power. Inverters add extra parts and lower efficiency but let you use everyday gear.
The Vansmith Approach: Our standard 2kWh Lithium smart power system gives both DC and AC power options, with upgrade paths to 5kWh or 10kWh based on your actual power needs.
Solar Power Van Conversion Systems
How Solar Power Works in Van Applications
Solar panels turn sunlight straight into DC power, which charges your battery bank through a charge controller. The system keeps making power any time the sun is shining, giving you renewable energy for your van life adventures.
Daily Solar Reality Check: A 300W solar system in good conditions might make 1,200-1,800 watt-hours per day, based on sun angle, weather, and system efficiency. Real-world output is often 20-30% lower than the rated maximum.
Solar Panel Types and Selection
Monocrystalline Panels - Premium Performance
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Highest efficiency per square foot
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Better performance in partial shade
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Longer lifespan and warranties
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Higher cost but better long-term value
Polycrystalline Panels - Budget Option
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Lower cost per watt
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Adequate performance for many applications
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Slightly larger for same power output
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Good choice for budget-conscious builds
Flexible Panels - Installation Convenience
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Conform to curved van roofs
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Lighter weight installation
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Lower efficiency and shorter lifespan
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Good for specific installation challenges
Solar System Sizing Strategy
The Vansmith Standard: 300W Solar System Our standard system has 300W of solar power, which gives enough power for:
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LED lighting throughout the van
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Water pump operation
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Phone and laptop charging
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Efficient 12V refrigerator operation
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Basic comfort and convenience loads
Upgrade Options: 5kWh and 10kWh Systems For higher power demands including:
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Induction cooking appliances
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Air conditioning systems
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Multiple high-power devices
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Extended off-grid capability
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Professional work equipment
Charge Controller Selection
MPPT vs. PWM Controllers Maximum Power Point Tracking (MPPT) units cost more but give 20-30% better results than PWM controllers (Victron Energy), especially in changing light conditions common in van life.
Proper Sizing: Charge controllers must be sized for both solar panel power and battery bank voltage. Oversizing gives room for future solar growth.
Battery Technologies and Selection
Lithium Iron Phosphate (LiFePO4) - The Current Champion
Why Lithium Dominates Van Applications:
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2,000-3,000+ cycle lifespan
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95%+ depth of discharge capability
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Excellent efficiency and charge acceptance
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Stable voltage throughout discharge cycle
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Lightweight compared to lead-acid alternatives
The Vansmith Standard: Our 2kWh lithium systems give steady power for normal van life needs while offering clear upgrade paths as needs grow.
Battery Bank Sizing Principles
Daily Energy Consumption Analysis:
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LED lights: 50-150 watt-hours per day
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Water pump: 20-50 watt-hours per day
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Refrigerator: 600-1,200 watt-hours per day
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Electronics charging: 200-600 watt-hours per day
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Total typical usage: 1,000-2,000 watt-hours per day
Battery Capacity Planning:
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Size for 2-3 days of energy storage
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Account for system inefficiencies (10-15%)
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Plan for future load growth
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Consider worst-case weather scenarios
Battery Management Systems (BMS)
Modern lithium batteries include sophisticated Battery Management Systems that:
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Prevent overcharging and over-discharging
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Balance individual cell voltages
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Monitor temperature and current flow
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Provide safety disconnection if needed
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Communicate with monitoring systems
Charging Systems Integration
Alternator Charging - Power While Driving
DC-to-DC Chargers: Modern vans need DC-to-DC chargers to safely charge lithium batteries from the alternator. These units ensure proper charging voltage and protect both the van's power system and your house batteries.
The Vansmith Advantage: Our systems include alternator charging built in, so your batteries charge while driving to your next stop.
Shore Power Integration
Ship-to-Shore Charging: When plugged into campground power or home power, your system should auto charge batteries and power van systems without running generators or draining battery power.
Automatic Transfer: Good systems auto switch between power sources without user input, making sure everything runs smoothly.
Backup and Emergency Charging
Portable Generators: For long cloudy periods or high power needs, portable generators give backup charging ability.
EcoFlow Integration: The Vansmith systems can work with EcoFlow portable power stations for extra power and backup power options.
Power Management and Monitoring
Smart Battery Monitoring
Why Monitoring Matters: Without good battery tracking, you're flying blind on power use and remaining power. This leads to surprise power outages and shorter battery life.
Essential Monitoring Features:
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Real-time voltage, current, and power display
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Remaining capacity estimation
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Historical usage data
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Smartphone connectivity for remote monitoring
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Alarm settings for low battery conditions
Load Management Strategies
Priority Power Distribution:
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Essential loads: lights, water pump, communications
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Comfort loads: fans, refrigerator, entertainment
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Luxury loads: high-power appliances, air conditioning
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Optional loads: non-essential convenience items
Automatic Load Shedding: Advanced systems can auto shut off non-essential loads when battery power drops below preset levels.
Inverters and AC Power Systems
Pure Sine Wave vs. Modified Sine Wave
Pure Sine Wave Inverters - The Professional Choice:
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Compatible with all AC appliances
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Clean power for sensitive electronics
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Efficient operation with quality appliances
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Essential for professional equipment
Modified Sine Wave - Budget Option:
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Lower cost but limited compatibility
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Can damage some electronics over time
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Inefficient with many modern appliances
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Generally not recommended for van applications
Inverter Sizing and Selection
Continuous vs. Surge Power:
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Size for actual continuous loads, not theoretical maximums
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Account for appliance startup surges
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Consider simultaneous load operation
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Plan for system efficiency losses
The Vansmith Approach: We size inverters based on actual usage patterns rather than rated maximums, making sure things run well without extra cost and complexity.
System Integration and Installation
Professional vs. DIY Installation
Why Professional Installation Matters:
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Electrical systems can be dangerous if installed incorrectly
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Code compliance ensures safety and insurability
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Professional installation includes proper testing and documentation
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Warranty coverage often requires professional installation
The Vansmith Advantage: Our team has put in hundreds of electrical systems and knows the wiring challenges that come with van builds.
Safety and Code Compliance
Essential Safety Features:
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Overcurrent protection (fuses and breakers)
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Proper wire sizing for all loads
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GFCI protection where required
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Grounding and bonding systems
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Emergency disconnection capabilities
System Documentation
Why Documentation Matters: Proper system paperwork allows easier troubleshooting, upkeep, and future changes. It also gives useful information for insurance and resale purposes.
Common Electrical System Mistakes
Undersized Wire and Overcurrent Protection
The Problem: Using car wire for house electrical systems or weak overcurrent protection creates fire hazards and system failures.
The Solution: Use marine-grade wire and proper overcurrent protection sized for actual loads and wire rating.
Inadequate Ventilation and Heat Management
The Problem: Electrical parts make heat and need good airflow to run well and stay safe.
The Solution: Plan airflow for all electrical parts and avoid installation in tight spaces without airflow.
Mixing Battery Technologies
The Problem: Connecting different battery types or ages creates uneven charging and lower system performance.
The Solution: Use matched battery banks and replace batteries as complete sets when needed.
Maintenance and Troubleshooting
Regular System Monitoring
Monthly Checks:
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Battery voltage and capacity monitoring
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Connection tightness and corrosion inspection
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System performance verification
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Cleaning of solar panels and ventilation areas
Annual Maintenance:
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Complete system inspection and testing
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Connection cleaning and retightening
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Component replacement as needed
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System performance optimization
Common Troubleshooting Issues
Low Battery Performance:
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Check charging system operation
If you’d rather have a skilled team design and install a solid van electrical system for you, explore our services and see how we can help.
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Verify load calculations match actual usage
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Inspect connections for voltage drop
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Consider battery age and condition
Solar System Underperformance:
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Clean panels and check for shading
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Verify charge controller operation
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Check wiring connections and voltage drop
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Assess realistic expectations vs. actual conditions
Future-Proofing Your Electrical System
Expansion Planning
Design for Growth:
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Include extra capacity in charge controllers
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Plan conduit and wiring routes for future additions
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Size battery bank with expansion capability
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Consider future load additions
The Vansmith Upgrade Path: Our systems include clear upgrade paths from 2kWh to 5kWh to 10kWh power, allowing growth as your power needs evolve.
Technology Evolution
Staying Current:
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Battery technology continues improving
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Solar panel efficiency increases annually
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Monitoring and control systems become more sophisticated
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Integration with smart home technologies
Real-World System Examples
The Weekend Warrior System (2kWh Standard)
Components:
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300W solar with MPPT charge controller
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2kWh lithium battery bank
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1,500W pure sine wave inverter
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Comprehensive monitoring and safety systems
Powers:
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LED lighting and fans
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12V refrigerator
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Phone and laptop charging
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Water pump and basic appliances
The Full-Time System (5kWh Upgrade)
Enhanced Components:
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600W+ solar array
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5kWh lithium battery bank
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3,000W inverter capacity
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Advanced monitoring and load management
Additional Capability:
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Induction cooking appliances
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Air conditioning systems
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Professional work equipment
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Extended off-grid capability
The Ultimate System (10kWh Maximum)
Premium Components:
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1,000W+ solar array
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10kWh lithium battery bank
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Multiple inverters for redundancy
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Comprehensive smart home integration
Ultimate Capability:
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Residential-level electrical capacity
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Multiple high-power appliances simultaneously
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Extended off-grid living capability
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Professional-grade work environment
Cost-Benefit Analysis
Initial Investment vs. Long-Term Value
Quality System Benefits:
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Reliable power for years of van life
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Reduced maintenance and replacement costs
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Better resale value for your van
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Peace of mind during adventures
The False Economy of Cheap Systems:
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Frequent component failures and replacements
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Poor performance leading to lifestyle limitations
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Safety risks from inadequate protection
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Higher total cost of ownership
Ready to Power Your Van Life Dreams?
Van electrical systems are complex, but knowing the basics helps you make smart choices about your power needs and system design. Whether you choose a pro install or tackle it yourself, proper planning and good parts make the difference between reliable power and constant frustration.
The key to successful van electrical systems is matching your system size to your actual needs while planning for future growth. Start with a solid base and proven parts, then expand as your experience and needs grow.
Remember that your electrical system is the base that makes everything else in your van work. Putting money into solid, well-designed power systems pays off through years of trouble-free van life adventures.
The VansmithReady to explore van electrical systems that really work? The Vansmith team has planned and put in hundreds of electrical systems for van lifers across every power need level.
From our standard 2kWh systems to top-end 10kWh setups, we can help you design and install the electrical base that makes your van life dreams real. Check out our full range of electrical services and installs at The Vansmith.
The VansmithYour steady power adventure starts with the right electrical base let's make it happen!
Frequently Asked Questions
What are the main components of a van electrical system?
Every van electrical system has four core parts: power sources (solar, alternator, shore power), energy storage (battery bank), power control (charge controllers, monitoring, safety gear), and power flow (inverters, DC distribution, outlets). These pieces have to be sized and matched so they work together reliably.
How does solar power work in a van electrical system?
Solar panels turn sunlight into DC power, which flows through a charge controller to safely charge your battery bank. As long as the sun is out, the system keeps topping up your batteries and reducing how often you need to rely on alternator charging or shore power.
How much power can a 300W solar system produce on a camper van?
In good conditions, a 300W solar setup can produce roughly 1,200–1,800 watt-hours per day. Real-world output is usually 20–30% lower than the panel’s rated maximum because of sun angle, weather, and system losses.
What’s the difference between 12V DC and 120V AC power in a van?
Most van-specific gear like LED lights, fans, water pumps, and many fridges run directly on 12V DC from your batteries, which is efficient because there’s no conversion loss. Standard household appliances need 120V AC, so you’ll use an inverter to convert 12V DC to AC, which adds components and reduces overall efficiency.
What type of solar panels are best for a van conversion?
Monocrystalline panels are the most efficient per square foot and perform better in partial shade, making them a strong long-term choice for most van roofs. Polycrystalline panels cost less but take more space for the same power, while flexible panels are lighter and conform to curved roofs but trade off efficiency and lifespan.
