How to make a solar water heater using solar panels for school projects ?
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Tools and Materials
Tools
Table SawHand SawDrill pressPower drill3/4″ drill bit1″ hole sawExacto knifeTape measureScrew driverDigital thermometerCaulking gun for adhesiveCoarse round file
Materials for collector
1 – sheet of Coroplast plastic sheet (4’x8’x4mm) cut to 22″x90″ – $8.501 – 4′ of 1 1/4″ ABS tubing – $6 (Note: Do not use PVC as it softens at too low a temperature causing leaks.)4 – 1 1/4″ ABS caps – $102 – threaded 1/2″ hose nipples – $1.001 – cartridge of silicone adhesive/sealant suitable for plastic – $3.50 (Note: since original publication I’ve found Marine GOOP to be better)1 – can of flat black spray paint – $5.00
Materials for frame
1 – 1/2″ sheet of plywood (4’x8′) cut to 24″x8′ – $8.001 – 3/4″ sheet of polystyrene (2’x8′) cut to 22″x87.5″ – $2.502 – 2×3 x 8′ – $8.00 used1 – at least 4’x10′ of transparent plastic sheet – $0 scrapmisc screws and staples
Materials for tank / water circulation
1 – cooler (or other water tank, preferably insulated) – $20 but I already had one scrap1 – 15ft of 5/8″ garden hose – $5.502 – 1/2″ hose clamps – $1.50
Total cost of materials = $59.50
Build the collector
Use an exacto knife to cut the corrugated plastic sheet to 22″x90″. When cutting lengthwise, be sure to cut in a single channel for the whole length.Cut the ABS pipe into two lengths, each 20.25″ long. Check that when a cap is placed on either end, the total length is 22″. I picked this width so it would fit between the roof rafters in my attic.Drill a 3/4″ hole in the side of two of the ABS caps. This will be easier if you pre-drill with a smaller bit and gradually increase the size.Enlarge the holes with a coarse round file until you can just thread in the nipples. I did not have a tap of the right thread, so I planned to just glue the nipples in place.Drill a 3/4 diameter semicircular notch in the end of each ABS tube. This is easiest if you clamp them end to end in a vise. Alternatively you could drill this hole in the ABS tube before cutting it, and then just cut through the center of the hole to make the notches. These notches fit around the nipple end when the ABS caps are in place.Using a table saw with a fence, carefully rip a slot down the full length of each ABS tube. The resulting cross section should look like a “C”. The ABS tube tends to compress as you cut, so that when you are done, the slot will not be as wide as the width of your saw blade. Feed each tube through the saw a second time to clean up the cut for a consistent width.Repeat the slot cutting process with the ABS caps, keeping in mind what direction you want the nipples to be pointing when the panel is fully assembled.Do a dry fit, assembling the ABS tubes, caps, and hose nipples. You may need to carve a bit out of the notch to get the slot in the tube to line up with the slot in the cap.Repeat the dry fit on the end of the corrugated plastic sheet. Carve up the ABS as needed to get a nice fit everywhere.
Tools
Table SawHand SawDrill pressPower drill3/4″ drill bit1″ hole sawExacto knifeTape measureScrew driverDigital thermometerCaulking gun for adhesiveCoarse round file
Materials for collector
1 – sheet of Coroplast plastic sheet (4’x8’x4mm) cut to 22″x90″ – $8.501 – 4′ of 1 1/4″ ABS tubing – $6 (Note: Do not use PVC as it softens at too low a temperature causing leaks.)4 – 1 1/4″ ABS caps – $102 – threaded 1/2″ hose nipples – $1.001 – cartridge of silicone adhesive/sealant suitable for plastic – $3.50 (Note: since original publication I’ve found Marine GOOP to be better)1 – can of flat black spray paint – $5.00
Materials for frame
1 – 1/2″ sheet of plywood (4’x8′) cut to 24″x8′ – $8.001 – 3/4″ sheet of polystyrene (2’x8′) cut to 22″x87.5″ – $2.502 – 2×3 x 8′ – $8.00 used1 – at least 4’x10′ of transparent plastic sheet – $0 scrapmisc screws and staples
Materials for tank / water circulation
1 – cooler (or other water tank, preferably insulated) – $20 but I already had one scrap1 – 15ft of 5/8″ garden hose – $5.502 – 1/2″ hose clamps – $1.50
Total cost of materials = $59.50
Build the collector
Use an exacto knife to cut the corrugated plastic sheet to 22″x90″. When cutting lengthwise, be sure to cut in a single channel for the whole length.Cut the ABS pipe into two lengths, each 20.25″ long. Check that when a cap is placed on either end, the total length is 22″. I picked this width so it would fit between the roof rafters in my attic.Drill a 3/4″ hole in the side of two of the ABS caps. This will be easier if you pre-drill with a smaller bit and gradually increase the size.Enlarge the holes with a coarse round file until you can just thread in the nipples. I did not have a tap of the right thread, so I planned to just glue the nipples in place.Drill a 3/4 diameter semicircular notch in the end of each ABS tube. This is easiest if you clamp them end to end in a vise. Alternatively you could drill this hole in the ABS tube before cutting it, and then just cut through the center of the hole to make the notches. These notches fit around the nipple end when the ABS caps are in place.Using a table saw with a fence, carefully rip a slot down the full length of each ABS tube. The resulting cross section should look like a “C”. The ABS tube tends to compress as you cut, so that when you are done, the slot will not be as wide as the width of your saw blade. Feed each tube through the saw a second time to clean up the cut for a consistent width.Repeat the slot cutting process with the ABS caps, keeping in mind what direction you want the nipples to be pointing when the panel is fully assembled.Do a dry fit, assembling the ABS tubes, caps, and hose nipples. You may need to carve a bit out of the notch to get the slot in the tube to line up with the slot in the cap.Repeat the dry fit on the end of the corrugated plastic sheet. Carve up the ABS as needed to get a nice fit everywhere.
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