This post documents the steps to mount a 120W solar panel to a pole.
I chose to use aluminum angle to construct my solar panel frame.
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I cut through the aluminum angle using a hacksaw.
I drilled the holes into the aluminum using a drill press and a hand drill.
To protect the steel pipe from the elements, rust, and corrosion, I sprayed it with a cheap, $1 can of black spray paint.
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Conduit connects to the solar panel and how the pole is concreted into the ground with rebar.
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How do you get conduit out of the boxes anyway? I think I spent way too much time trying to figure it out, trying to find the end of the conduit so I could pull it through the box. It may be easier to cut the box all the way open and remove the entire coil of conduit from its box. If you plan on using all the conduit for one job, why try so hard to preserve the box?
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Solar panel is mounted to top of pole and locked with a chain. Solar panel can rotate on pole and aim at the sun. To demonstrate that the panel is producing power, it is used to charge a portable 12V battery and air compressor. The air compressor then inflates the tires on a bicycle.
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Related Posts: Charging Cell Phones in Emergency – Plus How to Add Connectors to Solar Panel Cables
Alisa Mercer says:
Greetings. I am trying to build a racking system for 4 solar world 145 watt panels. Can you suggest how long the pole should be, the size of the pole, and framing. I like how you have your system…thanks
June 8, 2010, 2:46 pmEarl says:
The pole size would depend on the surface area of your panels, usually measured in square feet. So, if your 4 panels combined are about 35 sq. ft., then the pole could be: 3.0 inches in diameter, 42 inches in the ground, and 60~72 inches above ground. These figures come from Direct Power & Water with the disclaimer to “always consult your mount manufacturer for specifications for your site and mount.” Good luck.
June 8, 2010, 3:44 pmAlisa Mercer says:
Oh my Earl…thank you so very much…well I had contact Direct Power and they wanted $610.00 for a rack mount for 4 solar world 145 watt panels…I thought that was a bit much…so I have been reseaching to make my own rack mounts….so far you site is the best…I will update you on our progress …Alisa
June 8, 2010, 4:10 pmEarl says:
Thanks for the compliment.
That rack mount is costly. I understand why you want to build your own to save some money.
June 8, 2010, 4:14 pm