Upper Structure

Cut Lengths Worksheet

Use the worksheet below to calculate board cut lengths relative to the length and width of the solar panels.

 

Board Size	Name	Expression for Cut Length	Length
2x8	Main Support	(Solar Panel Length) - 2.5in =
4x4	Horizontal Support	(Solar Panel Width) x 2 - 2in =
2x4	Vertical Support	(Solar Panel Length) + 4.5in =

 

Main Support

Drill a 7/8” hole through the Main Post, 1 ¾” from the top.  The large 7/8” diameter allows the design to tolerate a hole that is not perfectly level (up to +/- 1/8” variation at both ends).

Using 2x8 boards, cut two Main Support boards to the length written on the worksheet (above).  Drill an 11/16” or 3/4” hole near the center of each Main Support, 2 ¾” from the top edge.  Attach the main supports to the main post using 5/8-11x10 hardware.  Tighten until the Main Support can be moved by hand with resistance.

 

Cut two 5 ½” end pieces for the Main Support from 2x8 fragments.  Pre-drill 3/16” holes through the Main Support boards into the end pieces and attach using 5/16x4 leg screws.

Cut a 5 3/8” section of 4x4 post.  Drill a ½” hole through the middle of a side of the 5 3/8” section for attaching an eyelet.  Pre-drill 3/16” holes through the Main Support boards into the ends of the section and attach using 5/16x4 leg screws.

 

Horizontal & Vertical Supports

Cut two 4x4 post sections for Horizontal Supports to the length written on the worksheet (section 4.1).  Cut one 18” section of 4x4 post for the Pivot Arm.

Drill 9/16” holes through the center of a side of the Horizontal Support sections.  Drill a 9/16” hole in each end pieces, centered and 2” below the top edge.  Drill one additional hole in the rear end piece (away from the direction of the sun) 1 ½” above the bottom edge.  Use the end piece holes to template holes in the Pivot Arm with the top of the Pivot Arm flush with the top of the rear end piece.