DIY Retractable Solar Panels on Speed Rail Arch – Cape Dory 30 Refit Part 4.
To maximize solar power in the restricted space on this 30-foot Cape Dory cutter (with electric propulsion), we designed this no-weld/no-bend method for a DIY retractable solar array arch built from Speed Rail fittings, aluminum pipe, and heavy-duty stainless-steel drawer slides. The two extendable panels stow flush under the two fixed upper panels while maneuvering in a marina or for low windage when sailing offshore in heavy weather. They slide out on tracks to deploy when needed at anchor or in moderate conditions offshore.
The arch is done but the wiring will be covered in a future video. Subscribe to follow the refit. For more sailboat projects, visit AtomVoyages.com
Parts List:
Eight pieces 6463-T66 schedule 40 polished anodized 1.25″ pipe sold in two pieces 23′ stock length. (we used about 36′ total) $270 total. It’s easiest to cut the pipe and angle on a chop saw but you can also cut it with an angle grinder or hack saw.
We purchased two pieces 1.25″ polished 6463 grade aluminum schedule 40 pipe in standard 23′ lengths from our local wholesale supplier. At $135 each it was cheaper than ordering 8 pieces of cut lengths online. Bright polished anodized aluminum pipe is twice as expensive as 6061 non-anodized and if you don’t have a local wholesaler then anodized pipe cost could be prohibitive, which is why most DIY builds choose non-anodized. In that case be prepared to let it weather into that dull oxidized appearance.
Note that pipe (like this Schedule 40) is measured by its Nominal Inside Diameter (ID), while stainless steel tubing is measured by its Outside Diameter (OD). This 1.25-inch pipe has an OD of 1.66 inches. If you’re building a larger arch, you’ll want to use 1.5-inch pipe (1.9″ OD). We used Schedule 40 because it’s plenty strong, lighter, and less pricey than heavy-walled Schedule 80.
Two pieces 6061-T6 3/16″ x 2″ x 62″ angle bar (NOT anodized) sold in one piece 25′ stock length $87. Anodized angle bar is hard to source and in this build it is not in a highly visible area so doesn’t matter if it becomes oxidized on the surface. A stock 25′ piece of angle bar is double what we needed but at $87 it was cheaper than buying two shorter pieces online. And we can use some of the leftover on other projects.
Speed-rail fittings:
1. Four pieces 1.25″ Tee-E $16.48 each
https://www.buyrailings.com/shop/variant/07060-5e-tee-e-aluminum-magnesium-1-1-4-ips-12794
2. Four pieces 1.25″ elbows $21.16 each
https://www.buyrailings.com/shop/variant/07020-3-elbow-aluminum-magnesium-1-1-4-ips-12035
3. Four pieces 1.25″ Rectangular Base Flange $22.34 each
https://www.buyrailings.com/shop/variant/27170-47-rectangular-base-flange-aluminum-magnesium-1-1-4-ips-12476
4. Two sets stainless steel drawer slides, 27 9/16″ closed length. McMaster-Carr Model: 13875A21 $80 each.
Solar panels:
Two 200 watt and two 100 watt N-type BougeRV 200w bi-facial panels. Because these are N-type bi-facial, shade tolerant, and wired in parallel, they will cope with partial shading better than standard single-sided P-type panels.
Clamps and fasteners:
We used two Garhauer Dinghy Davit Stern Rail Clamps 1″ to 1.25″ DD-SRC 1-1.25 $75 each. These tube clamps are not a perfect fit to 1.25″ pipe but are still useable. You can special order these clamps for 1.5″ tube for a better fit (model DD-SRC 1-1.5) or look elsewhere for different style cheaper clamps.
Fasteners:
16 sets 3/8″ stainless hex bolts sized for deck thickness and backing plates, nuts and washers for bases
12 pieces 1/4″ x 3/4″ flat head stainless machine screws for angles to pipes
20 pieces #10 x 1/2″ flat head stainless machine screws for Tracks to angle bars
20 pieces #8 x 3/4″ flat head stainless machine screws, nuts and washers, for tracks to solar panels
24 pieces 3/8-16 x 1/2″ Allen head stainless cone point set screws to replace Speed Rail zinc-plated steel set screws
AtomVoyages.com
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