Large solar array support beams

[s/v Jedi]

Done with fabrication, now it’s sanding and painting

[s/v Jedi]

Pads for mounting the beams on top of the arch tubing

[s/v Jedi]

That G10 bar stock is 2” wide and 1.5” thick

The tubing of the arch is 1.5” diameter.

[AKA-None]

That’s some serious work

[s/v Jedi]

And the pads for the struts.

Currently laminating the actual cassette that will sit on top of the beams.

[s/v Jedi]

Cassette rails ready for drilling and dry fit of the panels

[s/v Jedi]

Dry fitting the cassette with four solar panels! It fits!

[s/v Jedi]

Paint: two coats of Awlgrip 545 grey epoxy primer and now first coat of Epifanes Polyurethane in black.

We had to move inside because of high humidity outside.

Also, a test of the lashings to be used for mounting to the arch. It is actually a whoopie sling from 2.5mm Amsteel Blue that is tightened with a lashing from 2.2mm Lash-It.

[CaptainRivet]

Originally Posted by s/v Jedi

Paint: two coats of Awlgrip 545 grey epoxy primer and now first coat of Epifanes Polyurethane in black.

We had to move inside because of high humidity outside.

Also, a test of the lashings to be used for mounting to the arch. It is actually a whoopie sling from 2.5mm Amsteel Blue that is tightened with a lashing from 2.2mm Lash-It.

You lash the whole cassette to the arch???

[sailingharry]

Your mounts with the G10 (and your entire system) are an amazing, over designed thing of beauty. And a lot of work (which you clearly enjoy).

For those reading along at home, I have found a source for attaching things to my arch. Search on Amazon for "LED Bar Mount" and you will find a large assortment of aluminum brackets that fit various size tubes and have various attachment points. I've used them to connect my solar panels to my arch, and to connect my spin sheet turning blocks to my arch uprights. Prices vary, but typically under $10 per bracket.

No where near as refined as Jedi's solution, but thought I'd mention it as a useful thought.

[s/v Jedi]

Originally Posted by CaptainRivet

You lash the whole cassette to the arch???

Yes. The only metal connections are drilled and tapped M5 screws that mount the struts to the arch. The struts are mounted to the beams with lashings again

[s/v Jedi]

Originally Posted by sailingharry

Your mounts with the G10 (and your entire system) are an amazing, over designed thing of beauty. And a lot of work (which you clearly enjoy).

For those reading along at home, I have found a source for attaching things to my arch. Search on Amazon for "LED Bar Mount" and you will find a large assortment of aluminum brackets that fit various size tubes and have various attachment points. I've used them to connect my solar panels to my arch, and to connect my spin sheet turning blocks to my arch uprights. Prices vary, but typically under $10 per bracket.

No where near as refined as Jedi's solution, but thought I'd mention it as a useful thought.

A word of caution: this is our third array on the arch. The second one used very sturdy aluminum brackets, holding three LG 375W NeonR panels but hurricane Ian destroyed it by ripping the aluminum apart. Attached a picture of the array in full glory and one of the ripped apart fittings.

This new array is designed to survive this

Oh no, attachments don’t work anymore… I’ll try with a laptop later

[CaptainRivet]

Originally Posted by s/v Jedi

Yes. The only metal connections are drilled and tapped M5 screws that mount the struts to the arch. The struts are mounted to the beams with lashings again

Wow never thought of that. Top notch work and you have clearly a lot experience what and what not to do anymore.
Really looking forward to see that beauty mounted on the arch with the lashing.

[s/v Jedi]

Originally Posted by s/v Jedi

A word of caution: this is our third array on the arch. The second one used very sturdy aluminum brackets, holding three LG 375W NeonR panels but hurricane Ian destroyed it by ripping the aluminum apart. Attached a picture of the array in full glory and one of the ripped apart fittings.

This new array is designed to survive this

Oh no, attachments don’t work anymore… I’ll try with a laptop later

Okay, laptop does attachments so here they are

[sailingharry]

Ouch! Big flat surfaces with big winds make really big loads!


My new arch is being built with stainless mounting tabs directly welded into the arch, built for the specific panels (great for this round, let's not think about a future upgrade....). But, those loads are why I really struggled with my choice of panels -- 50% of my panels will be aft of the main arch structure, and 30% will be aft of the solar support extensions. I have serious concerns about the ability of a panel to self-support nearly 2' of surface aft of the last support. But in the 15 years I've owned a cruising sailboat, I've never seen winds over maybe 60 kts -- so the risk is fairly low...hopefully...LOL