Hunter 40.5 Owner Modifications and Upgrades

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Replacing the Solar Panel on a 40.5

posted 12-26-2022 by Rick D


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There was not enough wire length to simply cut the lead from the solar panel to the fuse. Instead, after a bit of fretting, I took a dremel cutter and cut around the old solar controller, trying to not cut more deeply than necessary..

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This is what I found after removing the top of the controller.

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Once I removed the insulator, this is what was left.

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The next trick was to figure out which wire was hot. I tied a couple of 9 volt batteries together and back-fed them at the fuse panel. In my case, it was the wire to the right. (It turned out that it was the white wire on my boat).

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I used a soldering iron to free up the feed lines from the solar panel. The next trick was figuring out the best way to connect them to the flat wire feeds of the new solar panel (courtesy of Hunterowners.com). I decided to solder them and cover with shrink wrap.

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Here is the final connection before shrinking the covers. Of course, you need three hands to hold the wires while soldering, so get a helper and dont frustrate yourself as I did. The factory bezel does not work, so I used the custom one available through the website. Looks and works well.

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