Surthrival Trailer Mark 1 Documentation #1 Building the Side Solar Panel Frame

I started this build with a sketch of how I would assemble the frame to attach the solar panels to the trailer. I deviated from this sketch to only have a support in the center of the frame to save on weight.

The frame was built from 1"x1"x .063" steel square tube and 1"x1"x.125" angle. The total length of the frame is 13'2" and the width is 3'3&3/4". I bought my steel (qty) 5 square tube and (qty) 3 angle as 20' "sticks" and asked them to cut all of them to 13'5".

This frame has the following cut list:

qty (2) 13'5" 1"x1"x.063" steel square tube cut at 13'2"
qty (1) 6'7" 1"x1"x.063" steel square tube cut at 3'1&3/4"
qty (1) 6'7" 1"x1"x.125" angle steel cut to 3'1&3/4"

I cut the steel with this 14" Rigid Metal Cut off saw.

I set the frame down on some 1/2 plywood pallets that I will use for my welding table to check the layout. The 1"x1"x.125" angle was set back to back in the center of the frame @ 6'6".

After my first cuts I double checked my measurements by laying over my panels and had to adjust my cuts.

Using a 220V stick welder and 6011 welding electrodes, I welded the frame in a jig on the welding platform. Using 3/4" plywood blocks the frame was squared by measuring from corner to corner to check its square. The the blocks were screwed in around the frame to hold in place while welding. The amperage was adjusted to around 80 amps to keep from blowing through the thin square tube.

The final frame was matched up to the solar panels. The welds were sprayed with simple green to clean the flux/carbon which will help keep the strength of the weld.

Thank you and stay tuned for the next build! @makinstuff