Pioneering the Solar Powered Tesla Cannonball Run

In a bold demonstration of off-grid electric vehicle potential, Joe Kliewer is attempting something no one has done before: a fully solar-powered Tesla Cannonball Run. Starting at the legendary Red Ball Garage in New York and ending at the Portofino Hotel in Los Angeles, Kliewer plans to traverse the United States using nothing but sunlight to power his Tesla. This remarkable journey not only challenges the conventions of EV charging but also showcases the power of lean engineering, modular solar integration, and energy independence.

The Setup: A Portable Off-Grid Charging Station

Kliewer’s build centers around an innovative mobile solar charging system. At its core is a Sol-Ark inverter/charge controller, which handles the conversion of solar power into usable electricity for the Tesla. The system also includes a 5,000 watt-hour lithium iron phosphate (LFP) battery — chosen for its safety, thermal stability, and symmetric charge/discharge performance without requiring active cooling.

Connected to this inverter are 64 flexible solar panels, each rated at 100 watts and utilizing high-efficiency Maxeon cells, the same found in the Aptera solar EV. These panels are only a few millimeters thick and weigh about four pounds each, making them highly portable and practical for deployment in the field.

To anchor the panels, Kliewer avoids using nearly 200 tent stakes — a tedious and time-consuming option — and instead employs garden-variety lag screws driven into the dirt. This method provides durability and wind resistance, critical for extended off-grid charging.

Charging Strategy and Range Planning

Kliewer’s approach is strategic and deeply influenced by efficiency. He plans to drive at night — ideally at 55 mph — to maximize range while minimizing disruption to traffic. Charging occurs during daylight hours, with each full charge estimated to take two to three days, depending on weather conditions. This requires a camping-style rhythm akin to sailing: when the “wind” (sun) is favorable, you go; when it’s not, you wait.

The solar array, once fully deployed, must generate enough energy to push the Tesla at least 300 miles per charge. In testing, Kliewer has achieved over 350 miles under ideal conditions. If he finds himself in a pinch, the buffer capacity of the LFP battery can provide another 17–18 miles of emergency range. The inverter, delivering up to 5,000 watts at 240 volts, enables vehicle charging rates of about 18 amps — approximately the maximum sustainable rate for his configuration without overtaxing the system.

Engineering Considerations and Lean Design

The engineering behind this project reflects Munro & Associates’ emphasis on lean design and modular efficiency. With two integrated MPPT (Maximum Power Point Tracking) charge controllers, Kliewer’s system continuously adjusts to extract the most power possible from the sun. The panels are wired in series-parallel — 16 in series, 4 parallel branches — optimized to meet the inverter’s input specs and reduce voltage drop.

Stacking the panels is another lesson in smart packaging: by interlacing junction boxes face-to-face, four panels only stack to the height of one box. This means the full set of 64 panels compresses to about a foot tall, maximizing space in the vehicle while minimizing weight and complexity.

The round-trip energy efficiency (DC–AC–DC) of the system is approximately 80%, which is impressive given the number of conversions involved. Cooling is another consideration — especially as ambient temperatures rise — but Kliewer plans to rely on Tesla’s built-in cabin overheat protection and potentially camp mode if necessary.

Real-World Variables: Weather, Shade, and Public Curiosity

Despite the planning, some variables remain outside Kliewer’s control. Chief among them: the weather. Cloud cover can drastically slow charging, requiring additional idle days. To mitigate this, Kliewer is bringing ample food, water, and camping gear. Once west of Colorado, he’ll enter Bureau of Land Management territory, where he can set up camp freely and remain self-sufficient.

Another issue is shading. Even a brief shadow across part of a panel string can reduce its output significantly. Kliewer is considering a protective perimeter to keep people or objects from obstructing sunlight during peak charging hours.

Cultural Touchstones and Personal Flair

Kliewer doesn’t shy away from adding personality to the project. As a fan of Back to the Future, he affectionately refers to components of the system with references like “plutonium,” “flux capacitor,” and “Mr. Fusion” — a lighthearted nod to the film’s futuristic energy sources. It’s a fitting metaphor: just as Doc Brown’s DeLorean bent the laws of physics, Kliewer’s solar-powered Tesla seeks to bend the limits of current EV infrastructure.

While playful, the goal is serious: to set a Guinness World Record for the first fully solar-powered EV Cannonball Run. And Kliewer is fully aware that he may only briefly hold this title before the likes of Aptera — with built-in solar charging and extreme efficiency — take it further. That’s part of the inspiration to attempt this now.

Solar Powered Tesla Journey Takeaways

For engineers, EV enthusiasts, and forward-thinking investors, this project illustrates several critical insights:

• Solar integration is viable for long-distance EV travel, though it requires patience, planning, and creative engineering.

• LFP batteries provide a durable, safe solution for off-grid use, especially when paired with appropriate charge/discharge limits.

• Round-trip efficiency matters. Achieving 80% round-trip energy conversion with commercial-grade components shows promise for off-grid microgrid setups.

• Lightweight, modular solar panels are key to practical deployment and transport — a principle that applies to many mobile energy systems.

• The right pace makes the difference. Traveling at 55 mph may not be flashy, but it’s the key to maximizing range and aligning energy input with travel goals.

Conclusion: What Comes Next?

As Kliewer prepares to document his journey on a dedicated YouTube channel — Solar Cannonball Run — his work stands as a proof of concept for solar-charged mobility. In a future where charging infrastructure may not reach every corner, the idea of being energy independent via the sun has broad implications, from emergency response to remote exploration.

Follow the journey, learn from the challenges, and imagine the possibilities. The road to a leaner, cleaner, solar-powered automotive future starts with bold experiments — and Kliewer’s solar Cannonball Run is one such step.

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