I looked around for a suitable manual tilt mechanism for a portable solar panel and didn't find anything suitable. Most of what I found was too small for my full size panels which weigh 44 lbs each, with dimensions of 66" L x 39" W x 1.5" D (1676mm x 1008mm x 40mm). Yes, these panels are far from ideal for portable deployment, but they match the two on the roof and I got a good local deal on them (no shipping). I have room to store them in my RV trailer that is out of the way and secure.
For the prototype frame, I bought 1"x2" T6061 aluminum that is 1/8" thick. My goal was to create a tilting frame that could be used to secure the panel to the ground and handle high wind gusts. Most of the supplies I used for this project were not optimal, but were what I had on hand.
The four length of rectangular aluminum are joined together using aluminum brazing. I used a Bernzomatic TS8000 MAP-Pro brazing torch from Home Depot along with Bernzomatic Aluminum Brazing Rods, also from Home Depot. This is a shade tree mechanics alternative to real welding. The thickness of the aluminum requires a good two minutes to get to the right temperature before the brazing rod will melt into the joint. There are plenty of videos on YouTube on how to do this. Look up the channel "See Jane Drill". She makes it look easy and for the most part it is.
The poles came from a Kelty Noah's Tarp. Originally the poles had four sections. I took them apart and used just two sections, adding holes as needed. I used a CAD program to figure out how long the poles needed to extend to support a winter angle for the panel as well as the minimum angle for the summer. Getting the minimum angle may require locating the foot of the pole outside the frame. I didn't want to cut the poles to a shorter length.
The elastic cords are temporary. I'm either going to use an adjustable bungee cord or a non-ratcheting 1" cam buckle strap.
There are four cabinet hinges used at the bottom of the panel.
When lowered down, the bracket that the tip of the pole comes up through is almost flush with the aluminum frame.
A closeup of one of the brazed joints. It may look like the aluminum pieces aren't touching, but they are. The edges were beveled to give the braze more metal to work with.
The original plan to secure the frame to the ground was to drill four holes in the frame and run spikes or lag bolts through the holes. I'm rethinking that. I became a bit uncomfortable with swinging a hammer a couple inches from my solar panel. I may attach paracord to the frame and run the spike or lag bolt through a loop of the paracord about 6" away from the frame.
The next frame (I have two portable panels) will be different.
For the prototype frame, I bought 1"x2" T6061 aluminum that is 1/8" thick. My goal was to create a tilting frame that could be used to secure the panel to the ground and handle high wind gusts. Most of the supplies I used for this project were not optimal, but were what I had on hand.
The four length of rectangular aluminum are joined together using aluminum brazing. I used a Bernzomatic TS8000 MAP-Pro brazing torch from Home Depot along with Bernzomatic Aluminum Brazing Rods, also from Home Depot. This is a shade tree mechanics alternative to real welding. The thickness of the aluminum requires a good two minutes to get to the right temperature before the brazing rod will melt into the joint. There are plenty of videos on YouTube on how to do this. Look up the channel "See Jane Drill". She makes it look easy and for the most part it is.
The poles came from a Kelty Noah's Tarp. Originally the poles had four sections. I took them apart and used just two sections, adding holes as needed. I used a CAD program to figure out how long the poles needed to extend to support a winter angle for the panel as well as the minimum angle for the summer. Getting the minimum angle may require locating the foot of the pole outside the frame. I didn't want to cut the poles to a shorter length.
The elastic cords are temporary. I'm either going to use an adjustable bungee cord or a non-ratcheting 1" cam buckle strap.
There are four cabinet hinges used at the bottom of the panel.
When lowered down, the bracket that the tip of the pole comes up through is almost flush with the aluminum frame.
A closeup of one of the brazed joints. It may look like the aluminum pieces aren't touching, but they are. The edges were beveled to give the braze more metal to work with.
The original plan to secure the frame to the ground was to drill four holes in the frame and run spikes or lag bolts through the holes. I'm rethinking that. I became a bit uncomfortable with swinging a hammer a couple inches from my solar panel. I may attach paracord to the frame and run the spike or lag bolt through a loop of the paracord about 6" away from the frame.
The next frame (I have two portable panels) will be different.
- I'm going to use 1"x1" square tube in the same thickness. The prototype is very sturdy. This thing isn't going anywhere. But it's rather heavy and adds more bulk.
- I'm looking around for someone that can TIG weld the joints instead of brazing. I'm signed up to take a class, but it isn't until December.
- I need a way to lock the panel to the frame when it's folded down.