DIY Solar - Episode 10 - Building a Ground Mount Solar Rack

In this episode, I show the ground mounted solar rack that I built for my twelve 255 watt solar panels. I started by visiting solarelectricityhandbook.com/s... to determine the optimal angle to set my rack for a stationary year-round set-up. After determining the desired angle, I laid a bed of gravel to the area to help keep the weeds and grass to a minimum. Afterwards, I installed five 4"x6"x10' posts for the top of the rack and then attached a couple 2"x8"x12' stringers to the tops of the posts using galvanized bolts, washers, and nuts. I then used my angle gauge to determine where the lower mount needed to be and how tall to make it. I used four 4"x4" posts for the lower mount, but I used a 4"x6" post for the middle since two 2"x8"x12' stringers needed to be butted together there. I then used some trailer suspension U-bolts to mount "Super Strut" channels between the two mounts. Finally, I used some Super Strut spring clips to mount the solar panels onto the super strut channels.

[@mgcnrgy]

Thanks For the information you are making my life so much easier. I appreciate all your details and parts lists. I have 24 100 watt panels so I’ll need a 30 foot version with the 10 foot rails with 4 panels per rail. The video looks fine and very informative ! Cheers.

[@issa3522]

This was by far the most useful video I did came across! I had exactly the same diy Solar project in mind but I couldn’t figure out the irradiance angle and thanks to your video, I’ve found all the information that I need for my off-grid project in Chadian’s Sahara desert region. A huge thumb up 👍 to you Jim.

[@shannoncalhoun3684]

Simple yet effective design. Appreciate you posting this video. I will be watching your variable angle mount video. I am seriously considering using this for my dyi ground mount.

[@jeffmaling9577]

Super Helpful Jim! Looks like a very simple and effective design.

[@G3ZYY]

Nice video and very useful. I'm looking at ways of mounting 12 panels also and your system fits the bill nicely. Many thanks.

[@vadadofthr3357]

Great Design! I have been searching for inspiration on ground mounts, your is by far the nicest DIY I have seen, thank you for sharing this with us.

[@wcpportfolio]

Awesome video. I hope to have a setup like yours soon here in Texas. Best of luck with all of your solar projects!

[@planecrazyish]

Very well thought out and put together , I may just do this! Great job!

[@leroywarner7354]

I’m so glad there’s so much information on the Valance batteries. I think they’re awesome I bought two used ones I have a phone charged thank you so much

[@sol.green.energy9515]

Really nice design I am going to use it often. Thank you

[@timreynolds2643]

good videos Jim, keep them coming!

[@heted1]

Great idea. I got a quote from a solar company to install 25 panels on the roof of my house. When I told them I wanted them on the ground, they added $7500 for the ground rack. I thought that was way too expensive. I’ll do the whole thing myself and save money. Your idea is what I think I’ll use as I don’t like working with metal.

[@jimginnyohio]

Good luck! I hope this works as well for you as it has for me. One thing I would do different next time though….instead of using the wood stringer at the top, I would use two of the metal struts 8 - 10 inches apart and connect the u-bolts to those. I’ve been battling those wood boring bees around my house. They seem to really like that top stringer for some reason. I’ve been spraying it yearly with orange oil to keep them away, which seems to work well. But the metal would eliminate the need for doing that.

[@southernohiosolarhomestead8477]

Nice set up Jim very nice

[@andrewborntrager7909]

Nice job. Thank you for the ideas.

[@thereseward7852]

Awesome video- very helpful!

[@robertosalas3735]

Hello, very good video. Congratulations.

[@mohamedsheikh2502]

Thanks for the great video , it is a lot of info. we can use for design

[@Superduty_59]

Very nice solar rack Jim!

[@jimginnyohio]

j jones Thank you!

[@paulsmith5213]

Nice clean job🇺🇸

[@mysolarexperience9051]

Nice job 👍

[@ridemfast7625]

Going to build my own PV system and am strongly leaning towards wood. If the PT lumber lasts 20 years, statistics say it will be on this earth longer than me :) I built a 24x36 deck from PT lumber 20 years ago and it still looks great. As do dozens of 4x4 fence posts that are also 20 years old. Seems like 4x4 posts also would work well with some cross bracing - the tall 10 ft posts braced to the short front posts.

[@ibezag0]

Great project , would have liked to known the build process as far as the in ground part

[@WiSeNhEiMeR-1369]

HOWdy J-G-O, episode 10 Thanks COOP ...

[@cutweldngrind]

Just passing by..... oh nice solar array....I need to check some of your other videos to see what this array powers. I have a 500watt array and wanted to order 10-250w panels for my other property.

[@ek9772]

Some sites recommend using the data for the worst month (usually in the middle of winter) in setting up an array to maximize production for that month.

[@anxiousappliance]

Props on the good work. I'd have notched the posts so the carriage bolts have no vertical forces, and, I know you're moving, but I'd go with posts mounted to footings above ground. Still - I'm just a guy in a couch....

[@jimginnyohio]

Yes, excellent idea of notching the posts to eliminate the vertical forces! I do indeed plan to go with above ground or metal posts at my next location. Thanks for your comments and suggestions!

[@timandjeniholland]

Awesome video! Good to see another Ohioan getting into solar! I'm in the process of building an array near chillicothe. 20x 335w panels. Im curious as to how effective yours has been? Have you seen any significant savings? Thanks!

[@indianajonze]

Great video. So helpful! Not sure if it was asked before, but what size bolts are you using to attach the 2x8s to the 4x6 and 4x4?

[@rickharold7884]

So cool

[@springer-qb4dv]

thanks for the nice demo. But I was wondering if it's possible to build without any superstrut which is pretty pricey - so basically all wood frame for solar panels. I see homedepot has cheap simpson strong-tie 90 degree angles which can be used to bolt solar panels on wood frame with screws. So no expensive hardware, just plain vanilla wood frame and some cheap construction angles should do the job. On the roof, expensive mountings are needed, but on the ground, we can do with plain all-wood mounts (if approved by local county building dept). I am planning to do single row solar panel all-wood frame which also can be adjusted for angle to the sun so it can be nearly horizontal during summer and at 45 deg during winter (for better angle and also keep snow off). Also each frame will be secured to the ground with several rebar rods pounded into the ground, nothing fancy (assuming it gets approved by building dept).

[@jimginnyohio]

Yes, there are many people that have built complete wooden solar racks. But if you go that route, there a couple things to keep in mind: #1: It will not be as strong. Remember that panels are heavy! A good strong storm/wind can add a lot of extra stress on the wooden timbers. #2: It will not last as long. Between the weather and wood boring insects, you could be replacing things in just a few years.

[@LandtoHouse]

Nice-looking mounting system. I believe I'm going to go with something like this. You showed the superstrut locking nut but how did that attach to the panel? Actually attaching the panel to the frame is my last uncertain step.

[@jimginnyohio]

I simply used a 1-inch bolt and washer inserted thru the manufacturer drilled holes in the aluminum frame of the panels. Of course you will need to match the bolt size with the thread size of the spring clamp locking nuts that you buy.

[@LandtoHouse]

@@jimginnyohio that makes sense. Thank you. I will have to check and see if my panels have a mounting hole in them.

[@johnlee7691]

Since solar panels sit above the metal frame, unless it is a bifacial, could you have turned the unistrut the other way. With he channel facing down, you could leave the bolt proud. The solar panel can sit above it. Now you would have the same problem when you secure the solar panels, but in that case you could use a piece of metal spanning the channel or you could even use the purpose designed spring loaded channel screws?

[@richardbuehler9275]

I am looking at a modified ground mount based on your build. Any thoughts on my using Secure Set instead of concrete. My concern is setting wood directly in concrete. Secure set from all my research will help preserve the wood and will be basically on par $ wise with concrete.

[@kevinf3845]

Good ideas, thanks! Can you show how you mounted/did the screw from the panel through to the Super strut? Because there’s limited access to it.

[@jimginnyohio]

Hi. I recorded a new video this weekend and showed that. The video is scheduled to post in a couple weekends. However, you can try using this link to view the video now. I hope it shows what you are looking for. Good luck and best wishes! kzbin.info/www/bejne/gaWZn42EfLSNbZo

[@cutweldngrind]

I bought 2.5kw in used solar for $577 delivered. I just uploaded a video and they seem to produce the power and more. I was going to buy 10 more panels but was really curious of the condition.

[@cutweldngrind]

Since I will use 3 solar panels in series I will either use 9 from the 10 I bought or will need to order 2 more panels. I cant wait to really use these.

[@hoffmantnt]

This looks like a great DIY ground mount. Does anyone make an inexpensive kit with all the required hardware? I have not found one yet :(

[@jimginnyohio]

Tom Hoffman Not that I’m aware of. That’s why I created my own.

[@BarryEvans66]

Great video thanksI have never seen an actual panel. I am assuming there is a lip underneath that you bolted onto?Does this ground the panel to the rail?

[@jimginnyohio]

Yes, there is a lip around the entire panel. It has holes in each corner and in the center. These holes are used for securing the panel to the frame. They can also be used for attaching a grounding strap or cable.

[@jefflane8508]

One suggestion... rather than expensive U-Bolts that need to be cut at the correct angle, could you just use a couple threaded rods and a coupler plate below the 2x8? In other words, make your own "U" bolt. This would also make putting the nut on easier since you just turn the threaded rod to screw it into the nut in the Superstrut. For the coupler plate below, you could even use a small scrap piece of Superstrut. Do you think that would work?

[@jimginnyohio]

Actually, I thought of that before working on this project. However, I decided against it for a couple reasons. The threaded rods are not hardened metal, while the u-bolts are. Also, the u-bolts were designed to to be under a car or trailer, so they are more weather proof than the threaded rods which would corrode quickly when exposed to the weather. I didn’t want to take a chance on the threaded rod for those reasons. Thanks for the suggestion though!

[@jefflane8508]

@@jimginnyohio Excellent points. Thank you.

[@jdoughawk]

Nice video. You’ve had this installed for a couple of years now....any rust and/or corrosion? Or is that stainless steel super-strut? Thanks

[@jimginnyohio]

No signs of corrosion or rust so far. No, it's not stainless steel. So far everything is holding up very well. Thanks for your comments!

[@klr650hub5]

Are you sure the unistrut will pass inspection.The state fire marshall here in iowa failed my project on every front.

[@klr650hub5]

What do you think this array averages/day in kw’s production

[@tanahiro26]

sorry for the question but i want to know how to screw the panel on the strut. I want to do something like this. beginner. do you have any video how you did?

[@jimginnyohio]

Scroll down thru the video comments. I answered that question earlier. Thanks.

[@timreynolds2643]

so the Sun grid tie inverter is able to get the solar power in phase with the power grid?

[@jimginnyohio]

Tim Reynolds Yes. It is a grid tie device that outputs a pure sine wave.

[@glenmac6504]

Looks great, how did you fasten the panels to the uni strut nuts?

[@jimginnyohio]

Simply used a quarter/20 bolt and washer thru the pre-drilled holes in the panel frame into the uni-strut nuts. This clamped the panels down to the struts.

[@MyGoogleYoutube]

What was your total cost for this?

[@GS850GLZ-82]

How did you tighten the bolts that hold the panels, the lip on the panels didn't look very big? Tnx

[@jimginnyohio]

There is about two inches of space between the frame of the panels and the actual panel. There is plenty of room to fit a wrench in there. Probably not a socket wrench though!

[@johnkelly8614]

Thanks Jim! How's it holding up for you after four years? Anything you'd do differently now?

[@jimginnyohio]

It’s holding up great! I hope to post an update video soon. I can’t really think of anything I would do differently since everything has been good.

[@johnkelly8614]

@@jimginnyohio Glad to hear it. Thanks!

[@rickjamieson6605]

Great project! Just got some recycled 260W panels and was looking for a budget ground mount build. Did you cut your U-Bolts before or after you installed them? I'm worried about screwing up the initial threading. Thank you for posting this on KZbin!

[@jimginnyohio]

Rick Jamieson I mounted one set full size and marked the u-bolts with a sharpie marker. After cutting this set, I mounted the struts to insure everything fit correctly. Then I cut all of the rest to match the test set. To keep from messing up the threads, screw the nuts onto the u-bolts before cutting them. After cutting them, you can back the nuts off to restore any damage to the threads. Good luck with your build!

[@taylormills08]

Run a nut down past your cut mark on the piece you want to maintain the threads on. Make your cut and when you remove the nut it will correct your threads.

[@ahhlifesgood1956]

Great video, what guage superstrut did you use? Thank you

[@ahhlifesgood1956]

I noticed that Home Depot is selling the Superstrut in 12 and 14 gauge, other stores online I noticed were varying widely in gauge thickness. Maybe I should ask what gauge you recommend seeing as you've already made the installation? I'm essentially copying your format 100% with each of my panels being 60 lbs a piece. Thanks

[@jimginnyohio]

@@ahhlifesgood1956 I used the heavier 12 gauge struts for the stationary ground mount. I picked up most of the materials for that at Home Depot. Good luck with your installation. Mine has held up excellent so far!

[@ahhlifesgood1956]

@@jimginnyohio thank you sir

[@rickyogles8854]

hey Jim what size of wire did you use two run two the solar panels . I'm getting a little lower voltage on mine at 50 foot it keeps the inverter power tracking a lot

[@jimginnyohio]

I used 8 guage. FYI, one of my units power tracks often too. I believe this is just a symptom of the cheaper devices.

[@rickyogles8854]

thanks man ill try the 8 guage wire . see if it makes a difference. cheap inverter

[@Yomammaswallows]

Looks great! How’s it been holding up?

[@jimginnyohio]

It is still holding up great. No problems at all. Highly suggested!

[@Showbizjoe1]

@@jimginnyohio nice set up. How many 10 foot pieces of unistrut did you end up using?

[@GS850GLZ-82]

Hi again. Did you mount the inverter close to the array or by your house?

[@jimginnyohio]

I mounted the inverter inside my house about 90 feet away.

[@lookatthisvidsandfun]

Don't you have rain on the site? Diging wooden beams directly into the ground would definitely not hold up for 30 years. At least not here in central Europe.

[@jimginnyohio]

Karl Zeilhofer Hi Karl. I used pressure treated lumber for this project since I plan to move into a new house within the next 5-10 years. If doing this for a permanent basis, I would use galvanized poles instead of wooden beams. Best wishes!

[@rasicule]

I didn't catch if you said the total cost of the ground mount. Do you have an approximate cost on the materials? Retail ground mounts seem unnecessarily expensive.

[@jimginnyohio]

I didn't list my material costs since those materials will vary from place to place and will likely change over time. However, if you view the "description" of the video, you can see a list of the materials I used. You should be able to use that to get an estimated current cost for your location. Good luck and thanks for your question.

[@rasicule]

@@jimginnyohio Excellent. I will run that calculation. Thanks for the quick response!

[@garyenwards1608]

Id like to build something similar. What was the height of your front and your back posts? Thank you

[@jimginnyohio]

That will depend upon where you live. I mentioned In the video a website you can go to for learning the best angle for your area. You will need to determine that angle to best determine the heights to use.

[@garyenwards1608]

@@jimginnyohio You are correct thank you for the feedback

[@NegritocitoCat]

I haven't heard yet what size or voltage or wattage your panels are for the thousand watt inverter. I probably missed it while I was paying attention to something else. I want to buy the cheaper 24-volt panels, but I don't know if that'll work with the 110 inverter. I'm assuming that it will but I don't want to assume.

[@jimstockton3326]

I am using four Sainty Solar 255 watt panels. 8.5A pmax, 30V pmax each. These are wired in series and parallel as shown in the inverter guide.

[@loungelizard836]

Excellent video and nice construction. What about corrosion? I'm under the impression that you can only mount aluminum-frame panels with stainless-steel hardware because of the corrosion problem (electrolysis). This would probably be a bigger problem for you in the Midwest. Have you seen any older systems using galvanized-to-aluminum mounting?

[@jimginnyohio]

I guess that's a possibility. I will keep an eye on my system to watch for signs of that. I'm not aware of anyone else posting issues with a similar racking system. And I know that many people are using the strut pieces as well.

[@indianajonze]

i would imagine a simple solution if you're in the process of building a system would be to use nylon washers at the panel connection points. that's what i'm going to do. as i'm thinking it through, it would probably mean using 1"x1/4" bolts instead of 3/4"x1/4" since the nylon washers are thicker

[@tjmooney4181]

Isn't it frustrating not being able to adjust for the different seasons and sun heights?

[@jimginnyohio]

Not at all. It was built for the optimal angle for spring and fall. During summer, there is more sunshine to compensate. During the winter, the panels are cooler,so more efficient. In any case, the output provides the maximum power my inverters are able to handle.

[@tjmooney4181]

@@jimginnyohio oh nice, good setup thanks for the advice

[@robertd6925]

Have you had any issues with the wood warping?

[@jimginnyohio]

No, none at all. It’s important placing the support posts close enough to each other so that doesn’t happen.

[@mrmike1271]

How much wind do you think it can handle

[@jimginnyohio]

We’ve had 60 mph winds since building it and no sign of weakness as of yet.

[@brbubba]

How did you get this approved? From everything I've seen a DIY support needs a sign off by a structural engineer.

[@edsmith4414]

No requirement for that here. I used 1 1/2" pipe set in concrete footers, with 3/116 galvanized angle Mig welded to the pipe, drilled to bolt panels to angle. Got 11kw on the system now. I'd be leery of using wood to hold a 20-30yr panel....suspect a lot of these ground mounts using wood will be back in 10-15 years rebuilding them.

[@TheSpidersoftheworld]

Where is here I would like to move there the building codes here in Illinois are insane we bought one of those metal car ports for 800$ they came and installed it 1 week later I get a letter for a fine not getting a permit to have that carport installed it's my property I don't get this shit.

[@AllAroundTube50]

@@TheSpidersoftheworld Yeh, it's pretty lame that you need approval to build anything on your own property these days. California is very bad - you need a permit for a backyard shed.

[@onlyscience7120]

Why not 2 metal plates with 2 bolts instead of the U-bolt ?

[@jimginnyohio]

You could do that too. I selected the u-bolts since they are hardened steel. They were also designed to be under a car or trailer, so they will handle the weather without rusting. Finally, I found it to be much less work to simply cut those to the correct length versus cutting and drilling metal plates to be the correct size, length, shape, etc.

[@diyjohn2197]

what type of bolt did you use to secure the panels to the frame

[@jimginnyohio]

I used a 1-inch long 1/4" bolt. The SuperStrut spring nuts come in several sizes and I the 1/4" size. I found the 1-inch length bolt to work perfectly with those.

[@diyjohn2197]

will a flat washer work with the 1/4 bolt or do you need something in be tween to combat corrosion

[@jimginnyohio]

diy john Yes, I did use a flat washer too. Actually, I double checked the bolt I used and it is a 3/4” instead. Specifically it is a 1/4” x 20 x 3/4 in course threaded zinc plated hex bolt. Home Depot SKU 504 505. The washer is a 1/4 in zinc plated flat washer. Home Depot SKU 326 484.

[@diyjohn2197]

Awesome video- very helpful! best one I have watched

[@MrSummitville]

@@diyjohn2197 Zinc Plated screws can rust and should *not* use with aluminum PV Panels. Use Stainless Steel.

[@007vsMagua]

Oh my GOD! How much do those solar panels weigh?

[@jimginnyohio]

About 45 pounds each.

[@MrSummitville]

Did this pass an electrical inspection, or is none needed in your area ?

[@wcpportfolio]

MrSummitville I’m curious about this as well. I have a small project of a 50 watt solar panel with battery and charge controller providing electricity to a surveillance camera. I hope I don’t need an inspection just for that

[@MrSummitville]

@@wcpportfolio An Off-Grid PV system for a low voltage Surveillance Camera may not need inspection.

[@wcpportfolio]

MrSummitville I called my local public works office (city of Houston) and they told me anything under 50v / 50w does not require an inspection

[@tombalato8924]

What is the space between your front posts and back ones?

[@jimginnyohio]

That will vary depending upon your desired angle and your geographical coordinates.

[@tombalato8924]

jimginnyohio what is yours though? I’m in southern Illinois!

[@jimginnyohio]

Tom Balato Mine are at 74-inches.

[@tombalato8924]

jimginnyohio being that yours isn’t adjustable. How does that work for efficiency when it shows me it could be between 28 degrees in winter, and 76 in summer? I was wanting to build it stationary like yours but get the most efficiency!

[@jimginnyohio]

Tom Balato The angle I set my panels at was the optimal angle for spring and fall for my area. During the summer, when the sun is higher in the sky, I don’t have the optimal angle, but I receive more hours of sunlight to make up for the small losses. During the winter, again not the optimal angle, but the lower temperatures provide higher efficiency of the panels since they work better when cool. I was willing to go with that trade off, opposed to the additional maintenance issues that arise with movable parts. When things can move, they break!

[@dyealive]

good info but the camera is all over the place

[@chrispcriddercridder6397]

you need to look into this ... dissimilar metal corrosion ... better vid is ... galvanic corrosion forms of corrosion ...

[@jimginnyohio]

I really don't think this applies to my setup since my panels are not installed underwater or in a damp environment. I am not located near any large bodies of water and I have good airflow around my solar rack. Also, I have inspected everything after a full year of use and see no signs of corrosion thus far. Thanks for the information though!

[@chrispcriddercridder6397]

rain , snow , humidity .

[@MotoMerica]

Good content but poor video quality. If you make your camera stationary and move it to several locations while not-filming between moves you will make a much better video. This one was very hard to watch with all the shaking and moving. Good luck with you solar rack.

[@JayDee25895]

yo

[@christophercudia8354]

juts put a long bolt through and you have to move panels flat in summer and move panels for winter sun // you lost in this set up

[@rontuengel5849]

Lights where are the lights? You forgot the lights! For 24 hour power supply 365 days a year just add lights! For wind power just add a fan! Hydro power just pump the water back into the lake!

[@solarnmore4443]

i can show you how to mount it on the roof without making HOLES

[@ewaa4152]

Holy... learn to use a camera!

[@jimginnyohio]

Go watch someone’s else’s videos….TROLL! You’re no longer welcome here! I see YOU have no videos posted, or subscribers! Who are YOU to tell others how to do it?