// Sunface Guncase — Roof-Mount Power System
A weatherproof Pelican case with a rigid solar panel bonded to the lid, designed to mount flat on your roof rack. Charges your gear while you drive, parks in the rain, survives the trail.
See the Components →
// What's in the system
Every part chosen for durability, compatibility, and real-world use. Nothing decorative.
1024Wh LiFePO4 power station. Lives inside the case or in the cargo area. Charges from the panel via XT60 passthrough.
21qt aluminum compressor freezer. Runs on 12V or AC. Fits the back seat of most SUVs. Keeps food frozen for days on solar alone.
Two modular drawer units form the cargo platform. Lockable drawers keep gear organized and double as a flat work surface.
1.5L glass kettle runs off the Pecron. Hot coffee or tea anywhere. Boils in under 4 minutes on shore power, ~6 on battery.
// How to build it
Five steps from flat-pack to roof-mounted solar charging station.
Position the Rich Solar MEGA 100 Slim on the Pelican V800 lid. Use Renogy Z-brackets (×4) to attach the panel frame to the lid's exterior. Pre-drill through the lid shell only — not the seal channel. Apply Sikaflex 221 around each bolt penetration before torquing down.
⚑ Center the panel fore-aft to balance weight on the rackCut aluminum flat bar stock to span the full width of the lid interior at each bracket location. These backing plates distribute the bolt load across the lid shell and prevent pullout. Drill matching holes, insert stainless bolts from outside, and torque against the backing plates inside.
⚑ Use fender washers if flat bar isn't available
Secure the aluminum flat bar backing plates inside the lid at each bracket point. These plates prevent the bolts from pulling through the plastic under load. Check alignment before final torque.
⚑ Stainless hardware only — galvanic corrosion is real
Option A (gland): Drill a hole sized to the BougeRV PG11 gland base, feed both 10AWG wires through, tighten the compression fittings, and seal the flange with Sikaflex. Permanent and fully waterproof.
Option B (XT60 bulkhead): Drill a clean 20mm hole in the case wall, press in the AMASS XT60E-M panel mount, and solder your panel leads to the inside terminals. The outside accepts any standard XT60 plug — disconnectable in seconds and looks purpose-built.
Use T-slot or U-bolt brackets through the case base reinforcement points. Torque to spec. Add rubber anti-vibration pads between case and crossbars. Do a shake test before driving.
⚑ Position panel facing forward minimizes wind lift// The complete build
Every component you need, priced out. Buy through the links on this page and you're supporting independent builders.
* Prices approximate and subject to change. This page contains affiliate links — clicking them supports this site at no extra cost to you.
// Who it's for
Built for anyone who spends time far from an outlet.
Keep a lithium battery topped off for lights, fridge, and comms on multi-day backcountry trips.
Supplements rooftop panels with protected, lockable storage for sensitive electronics.
Weatherproof power for fish finders, GPS units, and radios. The case doubles as gear storage.
A grab-and-go power system that charges on the way to a shelter or job site.