DIY 12kw ground solar array

I wanted to share a little about the 12kw ground mount array I've been putting together. I think it's a winner as far as costs go, but may not be for everyone in every type of situation. Still, I hope this serves as inspiration for those looking to cut costs and do things on their own. I'm happy to entertain suggestions and also happy to answer questions. Here's to becoming a net energy producer! I also wanted to give a shout out to DavidPoz who's youtube channel and comment section feedback have been instrumental in giving the confidence to tackle such a large (for me) DIY solar build.

[@DavidPozEnergy]

Great job. I like how you made adjustments to your azimuth based on your micro-climate and shading. I love all the diagonal bracing you have all over the place.

[@andrewhofmann5453]

Love your videos David.

[@rongray4118]

60' of array - fantastic. We will be mounting our array on top of a sea container sort of like this. Great video - thank you for posting!

[@andrewford80]

This system looks awesome. Thank you for making such an informative video. I wish I had space for a ground mount array like this!

[@anastigmatix4119]

You could keep the whole thing 3 ft off ground, no need to be level. Great job!

[@arminius301]

outstanding job with readily available materials, rather than spending an absolute fortune on "solar" specific posts etc! Running the various wires over 200 feet may degrade voltage. A combiner box might have served well in this case. Btw you sound exactly like Matt Damon! My hat goes off to you for your ingenuity and sense for becoming energy-independent! I'm working in the direction to have my family completely off-grid as well.

[@fullyelectric]

Hey i know this video is like 3 years old, however just like to get an update on how this array has hold up in 3 years, also where did you buy the post and sleeves? Thanks again

[@downhillwelder73]

I like the unistrut mounting .

[@rickharold7884]

Super cool! Thanks for sharing

[@contakt23]

excellent job , very thorough in the stability dept , i might suggest that where you ran the cables into the conduit that you protect the insulation with some kind of plastic grommet as the insulation on the cables will eventually wear without some protection from the metal , wind movement etc.

[@SuperWhizy]

Awesome showcase. Thank you.

[@TheDishDoc]

Nice work!

[@USA-GreedyMenOfNoIntegrity]

My 20.6 kw sits on top of 34 unistruts, lag bolted to 48 4x4 pt posts on a 36 deg slope. Array is also at 45 deg for better winter production. The rear of my array is 13’ from ground at the tallest point.

[@adamporter1680]

Where are you located? Do you have much trouble with snow load? I am thinking of using the big strut aka super strut to span about 10ft for a 15kw.

[@berlinjackson1847]

I like your solar panel ground mount

[@chucktrotter9699]

4.6.22 Thanks for making the video and talking about it. Question: where did you aquire the steel sign posts and sleeves?

[@mktwatcher]

Nice DIY Ground Mount

[@kdanagger6894]

I built a 3kW ground mount system and did some calculations to optimize the angle for highest power production year-round. I am around 41N, which means that the sun is 49 deg above the horizon on the equinoxes. I decided to set my angle to around 42 degrees above the horizon. That may seem backwards, but it's important to consider the average height of the sun above the horizon, not just he PEAK height. Also, solar production is diminished during the winter months due to much shorter days and atmospheric extinction, so it's worth trading off a little bit of (excess) summer production to help out when the sun is lower in the winter. Having seasonal adjustability is great, but I've quickly gotten tired of readjusting 30 panels every few months.

[@DIYSolarandWind]

Thank you, I need ideas for making a solar array.

[@bloodcarver913]

Put some flexible plastic tubing around the cables coming up from the tube in the ground. Make it water and insect sealed.

[@larrymeyer7064]

I am in south Or. I like what you have done. I am subject to county permit requirements. You did not mention permit for yours. I have already been told, if it is not a manufactured racking system, I will have to have private engineering statement drawn. Expensive. 30 400 W panels will not be missed. So I will have to get a permit. Thank you for your presentation.

[@ry2456]

I am in Northern Oregon and my county told me as long as the rack is under 10 feet in height the won't care about engineering. So that's why I am watching these videos for ideas. Mine will be plenty strong since I don't want damage. To much time, money and liability to not build a sturdy rack.

[@willrobertson826]

I like your mounting frame some links to where signpost tubing could be found would be helpful. Uni strut is a lot of fun I this k I would put a couple of ground rods to be safe

[@sgtspaulding9461]

I’m looking into building something very similar to this as I also have 32 panels. Did you have a materials list in the description or somewhere I didn’t see one? Thanks

[@wildwestunlimited]

Very nice job on the array as well as the video explaining what you did and how. The question that's always been in the back of my mind is, doesn't it hurt the solar panel if it's in the sun creating energy yet there's no connection for the energy to go to from the solar panel?

[@stephansmith1937]

In addition, from the top of the lower leg, come across horizontally with a square post channel to the rear leg, to take the stress of the solar panel supports. As the sps will buckle in a strong storm.

[@dnsfloren]

nice one

[@rocketsurgeon7057]

Thanks for the video. What was the cost of your ground mount?

[@fasnuf]

I'm also in Oregon near Albany. There was some online calculator that said the happy medium for 18* summer and 45* Winter for my lattitude ws 33.5*. What do you think?

[@gregalot200]

I would be concerned about grass fires taking out those low panels, maybe a rock bed for protection other than that nice job.

[@offgridmangogrower]

I like your slippery wire or conductors…what size and brand? Also like your creative use of unistrut catalog..!

[@user-uw2pm9mm3x]

We get strong wing gusts here in Las Vegas Death Valley area. Have you grabbed a hold of the frame and try to shake the hell out of it. I'm gonna try your method. Thanks

[@wiboater4]

How long is your wire run from the panels to the house and what gauge wire did you use?

[@offgridmangogrower]

How did you control back feed on panels due to shading?

[@mktwatcher]

The important part of solar design for a fixed mounted system is to capture as much total insulation for the entire year not just a couple of times through the year.

[@jrhamilton5521]

I have the 2” square metal sign post. Where did you acquire the sleeves?

[@Jaguilarjr54]

How apart are your ground posts from front to back and side to side?

[@gg-gn3re]

Yea you do need the grounding wire so good thing you ran it too. Just because they're in the ground doesn't bond or connect anything, earth doesn't work like that. The earthing bond is way more complex but anyway anything even like 1ft away can have a different voltage entirely so it wouldn't bond to your house at all.

[@xxonelastliex]

What app did you use to track the sun?

[@shawnbiggers2658]

Will the unistrut fit inside the sighn post tubing? If so what size? I plan on vertical solar, East & West.with sighn post and unistrot.

[@snake10566]

Does your grass continue to grow under the solar mount?

[@richpalmisano1740]

Nice job. Hope you got those sign posts from a yard somewhere. Seems like that was a pretty expensive option...

[@HomesteadingintheForest]

It’s expensive now, but I had a pile of them from other projects over the years. The price has gone up significantly on these posts unfortunately. I can’t find them for decent prices any longer.

[@richardbuehler9275]

A couple questions. Did you just drive the posts into the ground or did you set them into concrete? I looked at material you can get 2” or 1.75” post. I would use 2” and splice with tube inside, use a larger tube for the frame. Also what was your support spacing - N-W and E-W.

[@HomesteadingintheForest]

I used 2" and 2.25" inch tubes. The sleeves were 2.25" and the 8 ft segments were 2". I just drove the posts into the ground. Have had some heavy winds this winter and the array hasn't budged. That said, I have a forest of large trees that buffers the wind from the back. The spacing was two panels wide which turned out to be 160 inches or so for my 400w panels). I used 12ft segments of the square tubes. I ended up using some spare galvanized conduit with flattened ends to make corner braces to support the long length of the square tubes. This was very helpful in stabilizing the array. I don't have my measurements handy but the distance between the front posts and rear posts was probably about three feet. I wanted to make it wider, but this allowed me the most efficient use of the size of metal tubes I had on hand.

[@harlankraft578]

@@HomesteadingintheForest Great job! Impressive!

[@trumpingtonfanhurst694]

Those square signpost tubes are $120 now

[@mangannon1647]

where did you price them?

[@SetchiPaunda]

Love it and someone probably already commented this. But where your PV wire goes down in to the conduit. You need that sealed with a drip loop or weather head. other than that. I love unistrut, and have a design for a sun tracking model

[@aa-eq7fv]

show us your tracking model please

[@p5makersplace]

Given these panels produce D.C. current, and you mentioned in the vid you were running 200 ft. away, what was your voltage drop at the other end? Did you run individual cable, or run your feed in to an external electrical panel at the panels , combine them, and run one much large fee (1/0 or something like that) back to your house? Thanks for a great vid . All of your parts are pretty much available at home centers , so great vid for multiple mounting options.

[@MrMindlink]

12:27 - Noticed 4 pair at 10AWG.

[@gg-gn3re]

they produce dc voltage, not current. "DC" means direct current

[@danstenis660]

The end panels touching the ground can be elevated off the ground. There isn't any rule that says that all the panels have to line up in a straight line horizontally.

[@jimpowell9205]

How about a materials list? I, too, wish to do the same with 24 panels…..

[@mattwoody1089]

Hi whare did you buy the materials

[@blackntantoadshelleyishot1626]

How do the goats like it?? I imagined them standing on top as soon as you said it’s a goat pasture😂

[@Brad.W]

System looks good but I'm curious why Mount your panels left to right instead of up and down? I have a 40 panel 16.4 410 watt per panel system my installer stood them up and down instead of left to right which shaved off about 20 feet it is 16x45 ft putting them long ways like you did 16 ft by 60 ft.

[@Glidedon]

He explained his decision in the video.

[@kameljoe21]

The only thing I have a problem with is that the panels are way to low to the ground. Where I want to install my panels we will end up with rock stikes from mowing.

[@awesomedee5421]

how come you didn't just make the array parallel to the ground? Where did you find those sleeves and 45 unistrut piece?

[@stephenross4333]

He explained why in the video. He's in Oregon, and the sun goes very far down on the horizon on Dec 21st up herer in the Pacific Northwest. He angled it to more closely match the spring & fall equinox (March 21st & Sept 21st).

[@markrobinson8539]

Were you able to do any wind loading calculations for your array ?

[@HomesteadingintheForest]

I hadn't. I will be checking with a solar builder in the area to get an opinion. I have a couple options to stabilize the array if it needs some help. I think it'll be fine, though.

[@glee21012]

@@HomesteadingintheForest Until it blows away, needs to be engineered properly, your local jurisdiction allow that? Its all fun and games until high winds send a panel flying.

[@HomesteadingintheForest]

@@glee21012 Yeah, no shit. It survived the winter including points with very heavy winds and did not budge.

[@niktak1114]

@@HomesteadingintheForest how much concrete did you use per post?

[@gg-gn3re]

The physics math on those panels around 41lbs weight and 45 degree angle at vertical is 85 miles per hour to flip them them without being bolted at all, just leaning against something. So at bolting it'd be more than double that

[@idontwantahandle._.]

are there any building code requirements for that homemade rack?

[@unionse7en]

in most places you need to be code compliant. That means buying a system with engineering approval from the manufacturer or id your own design getting it approved by a state recognized engineer. I have not seen one DIY rack that went through the engineering approval process. I am a mech engineer, I might consider designing my own rack and getting a recognized engineer to approve it, but I suspect it may be more $ than buying a system that is approved. I am developing bare land in an area that requires permits, so inspectors will be around to approve my entire site. These diy videos are where they already have established dwellings and are not worrying about inspectors coming around. Even though I will be entirely off-grid, inspections are required in my county. A big reason is if there is a fire, the firefighters have to be protected from electrical hazards (especially important or roof-mounted panels).

[@allent1034]

Wouldn't you need a Combiner for that many panels?

[@MartinLV.]

Hi! Wondering how the array held previous winters? it looks scary, pretty large wing with pretty small metal framing....

[@HomesteadingintheForest]

Doesn’t budge in winter storms. I put it in front of some thick forest, so there’s a bit of a wind break. Still, it’s seen some heavy winds has been great. If I didn’t have the windbreak, I’d probably set the posts in concrete for ballast.

[@MartinLV.]

@@HomesteadingintheForest thanks mate!

[@ArthurDentZaphodBeeb]

Any issues/concerns with uplift on those posts? I suppose no engineered drawings were needed...

[@HomesteadingintheForest]

I’ve watched them through three winters now and some heavy winds, and nothing has budged. I think soil type will have an impact, as will where you put the array. Our soil is clay, loam so things really stick in well, and there’s a large group of tree at the north end that acts as a wind break. I would have added ballast if I was concerned, but this seems to be a winner for me

[@ArthurDentZaphodBeeb]

@@HomesteadingintheForest Great to hear. How did you drive the posts? With a pneumatic post driver?

[@HomesteadingintheForest]

@@ArthurDentZaphodBeeb I used a cast iron driving cap sized for the posts and sledged from the top of my truck bed. Also dug down a couple feet with post hole digger.

[@earthenergyhex]

must have cost alot for that rack. It is a nice one though

[@pip5461]

That couldn't have been cheap to buy all those panels...

[@ut95awd1]

3 year old video, those stop sign posts have more than doubled in price! 😢

[@Jennifer-007]

So many questions asked in comments about sourcing as no details in description despite him saying he would, typical… nice system but useless video if no details and you ignore your commenters.

[@wildcoastbrew]

Apologies to all. It’s not a straight forward answer with how prices of steel went up during the pandemic. You have to search for square 2 inch metal sign posts and sometimes go pages deep before you find a deal worth jumping on. I have sources mine through many places over the years. All the components to my system were sourced all over the place as I hounded for the best deals I could find. I wish I could give you an easy answer, but the truth is sourcing the material is a lot of time searching the internet and prices change frequently, and deals can be had during one period that may not exist in another.

[@bw3506]

Pretty closed minded to call it useless. Sorry you get disappointed when someone else doesn't do your research work for you but prices and availability of things change rapidly anyway. Honestly if you can't figure it out you probably shouldn't be jumping into a DIY project of this scale. So many variables in construction of something like this. A material list needs to be custom made by you. Panel size, type of ground, location of site are just a start of variables to be considered. While it wouldn't work for me as is due to space and wind loading it gave me creative ideas. His video was helpful in showing use of a different material as well as his compensation for tree shading and fog, as a lot of inexperienced people might not consider this. Besides that it was free??

[@gg-gn3re]

@@wildcoastbrew different account? I think buying struts and welding them together comes out around 1/3rd the price of these square ones. So if anyone is going that route keep that in mind

[@MrSteeDoo]

this guy smokes dope.

[@mycomputer87]

You need heavier steel in your bulid, it's going to fold on you.

[@HomesteadingintheForest]

What informs your opinion and by what year can I expect it to fold? It’s been through three winters in the mountains of Oregon and it’s held strong in the biggest of wind storms.