How to Build a Solar Concentrator!

Today we show you how to assemble (in detail) our solar concentrator that we demonstrated in our last solar video. We give you step by step instructions that you can follow to build your own.

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[PuppetMaster]

I don't comment often, but I truly love what you are doing. I've never had much interest in engineering, but you make it accessible to those who don't know much about it. Thanks for all that you do!

[DerekWoolverton]

If you're going to be making a few of these, they make saw blades rated for non-ferrous metals that will easily go into your "chop" saw (we call them miter saws).

[gregb]

It's not just saving the cost of buying more panels, it's all the supporting electronics that go with it. like the charge controllers, etc. This is making each of those more efficient too.

[KylejvT]

Even with no welding experience or even a welder you could use a gas burner and aluminium brazing rods to join them. With a pit of practice you can create joints that are stronger than the base material itself.

[ClintonRyanThompson]

It would be interesting to see a way of automating the reflection angle using an Arduino and light sensors or even based on time. Great content - thank you for all the videos you guys make!

[jamesbarisitz]

Now a build an automated solar powered tracking system. Off the shelf parts and homemade ones are always a good mix. Clever design and tips for these reflectors.

[jaceyrector]

“Even if you’re not building them, you might find some of the tricks useful” is the theme of your channel. Good stuff as usual.

[benthere]

You could "solder" the aluminum pieces together with Alumiweld rods from Harbor Freight and others. It produces a strong joint with a propane torch. I have made reasonable cuts with a hacksaw and a miter box. The Alumiweld can bridge minor imperfections to make a very attractive joint. Prep the surfaces to be joined with a stainless steel brush prior to welding.
Thank you so much for all of the fantastic projects you feature.

[typxxilps]

extraordinary great content from the top to the bottom when touching such tiny details as in this video.
You can not get lost. Great work, great progress and many, many good ideas that usually suprise and fascinate me.

[RyanSmithElectroseed]

You are a genius. I'd love to see you do some experiments on heat storage and heating a house in the winter. I bet you could design something that basically runs itself for free.

[davidfisher]

I live in southern Ontario Canada. About 15 years ago a local farmer began erecting some free standing, tracker style arrays. These arrays were designed with vertical strips of solar pannels separated by reflective Periaktoi columns. The third side of the columns was reserved for attachment. Unfortunately these units suffered from wind damage…but I think he had a great idea!

[HeegeMcGee]

Thanks so much for the tips on aluminum framing! I'd like to use those techniques to build a 6U synthesizer case. Your video has more information on cutting aluminum than most others on YouTube. CHEERS!!!

[WillProwse]

Considering how cheap solar panels are these days, is it cost-effective to build these reflectors? Every time I have built solar reflectors, I realized that buying a second or third panel cost less money and produced more energy over time.

How much is the total cost of materials for these reflectors?

Even if you are pulling 60% of STC output from your panel during winter (what my system is currently outputting at my latitude), having 2X 100W solar panels would still produce more than a single panel with reflectors. If those reflectors are cheaper than a single panel (sometimes you can find them for $65!), they should be cost-effective.

This is also true when you are far from the equator. We have folks on our forum who are near the Arctic circle, and they over panel their systems, but do not bother with reflectors.

We do have some large solar installations out here in the desert that have mechanisms for tilting the panels, but I have not seen a single solar farm use reflectors on crystalline silicon based solar cells. There must be a reason for this.

That reflective material looks great! Super shiny. Well done video as always!!

[bknesheim]

Aluminium can also be cut in a manual miter saw. When you do it is a lot easier to control the small fragments from going everywhere. The fragment can short circuit electrical tools and other equipment.

[NICEFINENEWROBOT]

Hi! Yours is on of the shortest introductions to your videos, I like that. Just "Hi!" and there you are. Great move.

[damustermann]

I did cut a lot of miters on my chop saw, a quick tip if you cut small pieces: Tape the small cutoff to the saw! Either the fence, the table, or both. It works with just painters tape.
When cutting, the first corner went to the moon somewhere, after the taping they stayed right where they were. It takes just seconds to set it up and don't tape it to the stock that remains on the saw, because you will of course cut the tape too. Hope it's clear what I mean.

[BritishBungler]

That's one hell of a garage/shop. So envious.

[QuentinQuark]

Brilliant. Thanks for figuring out such a great way to do this, and then sharing it freely. I especially like the pre-tension to make the surface super flat!

[narnbrez]

i'd love more general machining/fabrication tips; you and dan gelbart make youtube worth a million bucks! edit: your tension trick is very clever!

[Mike-jvil]

I know it's already been said, so I'll vouch for the aluminum brazing rods.. I've personally repaired radiators and even the power a steering bracket on my classic car. that was years ago and it's still holding.. .also I appreciate the video's you guys are making. thank you very much.