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Mark-1 solar frame design:




The first supports I built were a set of "solar frames" out using sticks of aluminum "C-channel". Like PVC,
they come in sizes that can nest snugly with the size above and below them, which helps with construction. I
knew they were going to be really floppy, but was hoping that once the panels were zip-tied down that would
stiffen them up. The minimal construction using aluminum makes these frames really light for their size, but
it also makes them vulnerable to wind. So that's my next challenge, figuring out a better way to secure them
when it's windy.

Construction was pretty simple since I was using all the aluminum sticks at their full 8-foot lengths, so no
cutting was required. I just had to drill the holes and bolt them together. I used wing-nuts and marked the
sticks after assembly. Then they were disassembled to be assembled on-site, since transporting 8x8 frames would
be difficult. I found that the ends that dove-tailed into the larger sticks needed to be slightly sanded down
to fit in easily.

Unfortunately, this design had several drawbacks. The first test was winter field day, right after we received
almost a foot of snow, so assembly on-site was going to have to be done indoors. But the doorway wasn't big
enough to let out an 8x8 frame diagonally, and space in the cabin was limited. So I mostly assembled it in the
cabin, struggled to get it out the door, and finished the assembly outside. But then I also had to tie down
the panels outside in the cold and deep snow.

It worked, but the results were mixed. The panels didn't really add any stiffness to the frame, and it also
sagged badly in the middle. But given the short amount of time I had to build the frames, that was the best I
could have done in the short time I had. Even with the 100% overcast for the entire event, the panels were
able to harvest a good amount of power, so the idea of a solar frame was validated, but some improvements
were going to be needed.



2023.01.28 winter field day :



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