Want to build my own aluminum frame for 2 Hanwha panels

[John Calf]

Hello everyone and thanks for having me.

First and foremost let me tell you all that I'm cheap. I really don't mind spending money but when I can build something myself, which I love doing, I will.
I'll be installing a solar system next spring at my cottage. I pretty much know what I'll be using.
I want to build my own aluminum frame for my 2 Hanwha 295 watts panels which I'll buying in the next couple of weeks. I have a 2.5 inch steel post. I want to be able to tilt and swing the panels if need be.
Can anybody steer me towards a good video or DIY link? I googled and really didn't find anything concrete. Not in an urban setting so shipping would be expensive.
TIA

[John Calf]

Did some searching and looked at my friends set up, I think I can figure it out. I'm trying to delete this thread but can't figure it out so if the moderators can, do it please.
tks

[Rob Beckers]

Hi John,

Good to hear you figured out a way!

I try not to delete posts (other than spam), it messes with continuity. Besides, there's always something to learn from other people's posts. In your case, why not post a picture or two after you build the racking, so others can use the idea too?

-RoB-

[John Calf]

Sounds like a plan! tks

[John Calf]

Here's a few pics of my newly fabricated rack, copied somewhat from what I've seen on the net and one of my buddy's setup. The pole mount shown is an online mount, I will be fabricating my own, like I said, I'm cheap but I enjoy building these things and I have the time now that I'm retired.
The only thing I see that I'm not sold on are the U bolts, they're soft metal. I'm thinking of beefing them up with maybe thicker threaded rod or at least heavier metal.
I made the rack for 3 panels, only 2 mounted for now but the strut channels are long enough I can add another 39" panel.

I'm still not exactly sure how much energy we will need, we're not really big consumers (not planning on running an ac fridge,maybe a 24 volt), so mostly for lights, small appliances, tv, etc. My set up is for an off grid three season cottage. Getting tired of hauling jerry cans of gas by boat, filling the generator, etc.
Sorry for the long winded post, I know the thread title was about aluminum racking but I choose galvanized steel instead, heavier but much, much cheaper, lol.

[Rob Beckers]

Good looking mount John!

Unistrut is great stuff for fabricating lots of things, and as you say, aluminum has become expensive!

In our general area two of these panels should bring in around 1.6 kWh total per average day from spring through fall. A small fridge, unless it's a very efficient one, would use up around half of that. That's regardless if it's AC or DC, just that for an AC fridge you also have to run an inverter, and that adds another 0.5 kWh/day or so.

-RoB-

[Ralph Day]

John, if you're not satisfied with the u bolts, head to a garage that does spring/suspension work on buses, tractor trailers and the like. In my area the garage can fabricate/bend you bolts in many rod sizes, round or square and thread the length you need. Great resource to cultivate.

Ralph

[John Calf]

Good looking mount John!

Unistrut is great stuff for fabricating lots of things, and as you say, aluminum has become expensive!

In our general area two of these panels should bring in around 1.6 kWh total per average day from spring through fall. A small fridge, unless it's a very efficient one, would use up around half of that. That's regardless if it's AC or DC, just that for an AC fridge you also have to run an inverter, and that adds another 0.5 kWh/day or so.

-RoB-
Thanks Rob, yes I will be using an inverter. Since I won't need power after the lights are out, so to speak, I plan to remotely just turn off the inverter during the night thus saving power when inverter is idle. I have enough dc lights in the cottage to satisfy our needs.

[John Calf]

John, if you're not satisfied with the u bolts, head to a garage that does spring/suspension work on buses, tractor trailers and the like. In my area the garage can fabricate/bend you bolts in many rod sizes, round or square and thread the length you need. Great resource to cultivate.

Ralph
That's pretty much what my intent was, thanks