I wanted to add solar panels to my travel truck, which meant installing a sturdy rack to mount the panels on. Instead of buying an expensive roof rack system, I commissioned a simple steel rack at the SLO MakerSpace, and then installed it on the fiberglass camper shell using stainless steel hardware, DIY neoprene gaskets, and a lot of silicone sealant. The solar panel mounts are bolted onto the rack, so we can swap in new brackets if we want to upgrade our panels, or remove them completely and have a cargo rack.
First, I put the rack on top of the camper shell, making sure to align it on all sides. Then I stuck blue painter's tape under each mounting foot, marked the spots for the mounting holes, and removed the rack. Here's the process we used for drilling through the fiberglass, which turned out to be super easy:
I drilled all 8 mounting holes with no problem. Using the drill bit as as guide, I measured the thickness of the shell at 1 inch, so I needed bolts about 1.5" long to accommodate the mounting washers and nuts.
Next, I cleaned the rack and panel mounting brackets with mineral spirits to remove grease and dirt, then gave them three coats of black semi-gloss spray paint. The spray can handle is definitely worth the extra $5.