How to make DIY Fold Out Solar for portable deployable all weather panel
- Jul 1
- 4 min read
I wanted to add a solar arch to the boat and the panels I was interested in were the Renogy Bifacial Panels. Which for specs and refernce I got on Amazon https://amzn.to/4v5HXd8 The main reason was both the weight and physical size of them being suited for my boat. However making a solar arch with stainless steel is expensive. I was looking at the premade solar panels and have tested out the VTOman 400w which a couple of my friends have. But they are not all "weather sealed" since I wanted to have a solar arch I decided to go for the Renogy Bifaicials make a kick stand and place hinges on so that I can stow them away which will be a solution for the next few months while I save up for the stainless steel frame.
Why Bifacial Solar Panel
Bifacial solar panels capture sunlight on both the front and back surfaces. Unlike regular panels that only absorb light from one side, bifacial panels increase energy output by using reflected light from the ground or nearby surfaces. This feature makes them ideal for portable setups where sunlight conditions vary. They look nicer from underneath and you get the boost from the reflection of the water and the white deck.
Above is the kickstand that I made using 21.5mm "Overflow Pipe" A couple of 22mm elbows and 22mm T pieces. The pipe is semi flexible are strong enough for my 250w panels which weigh 12.5kg each.
They are connected to the solar panel using 1 of the existing holes either side of the panel. The U shaped clips are called 20mm "Space Bar Saddle" they fit inside the panel and hold the horizontal bar in place. I drilled a second hole using a drill piece with electrical tape so that the drill did not go into the panel. I also swapped out the screws for stainless steel ones and used PTEF tape so that there's no metal on metal to slow the "Galvanic corrosion"
For the hinge I used a stainless steel Steel Ball Bearing Hinge - 102 x 76 x 3mm. This was wrapped in weather tape so the aluminum solar frame was not in contact with the stainless steel. Although I want to build the arch soon, I'm also on a tight budget as both work has been slow at the start of the year and I'm saving to buy a van. I did need to drill a couple more holes in the panels for the hinges and added spacers behind all of the screws (while I was building it) then an extra spacer on the opening side of the panel. This is to help the solar suitcase not 100% close so there's no stress on the hinges.
If I was to ground mount these on the grass I would peg them down using large tent pegs. Or weigh them down. The ground horizontal bar has a couple of holes in them for drainage for condensation build up or water getting in.
What's next
To get the solar to work you either need an all in one powerstation these have a battery and solar charge inside. My Bluetti powerstation is discontinued and is about 5 years old. If your looking for easy home back up which can work with air friers, washing machines then the ones I have on this page https://amzn.to/4oVW6s0 are the ones I was considering for my parents. The one at the start of the list the "AFERIY P310" is the one I ended up buying for my parents.
The Fold-Out frame
Parts I used per panel (To make the 1 fold out with this panel I ordered 3x3m pipe) 21.5mm Over Flow pipe 2x 22mm T-Pieces 2x 22mm 90* Elbow 2x 20mm Space Bar Saddle It's cheaper to buy them in the multipacks - The list includes the fold out solar panel, simular parts used the panels I purchased and the powerstation you see in the video. https://amzn.to/4gLu0O8
How will I be using the panel?
In the picture you can see my all in one powerstation. In the video you see some of my sail boat which has a victron system that I put in place. I'm going to add a 48v battery switch between the solar panel and the victorn mppt. This way I can divert the solar power to either my house bank or my powerstation. While I run the engine the batteries get charged by the alternator and the solar becomes a bit redunant. I also have 2 more panels the 200w shaddowflux and a sunpower 170w flexible panel on the sprey hood.
Is this design for you?
If you are looking for a semi long term, portable deployble set up this could be a good solution. For example you have a balcony solar set up at home. You rent somewhere and cant permanently install things. Perhaps you go to places for a few weeks at a time and don't move very often then yes this is good. The bifacial panels work well the down side is over all the 500w system does weigh 26kg. For me this is fine as i'm stronger than I look. However if your on the go constantly and you want something to pack away then the premade ones are probably better due to the weight and they're made of plastic. You could use the design and buy flexible solar panels and adapt it to this for lighter weight. This one by 200w Xinpugang flexible panel had good reviews on amazon https://amzn.to/3QBt3xn
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