04/13/23

Save energy and save money Today

1

Solar Heater Project 2011 designed by Paul Cabral

04/13/23 Save energy and save money Today

2

Summary

What is Built will workFinal cost and material listHow to build your very own Solar

Heater with common tools

04/13/23 Save energy and save money Today

3

Progress

The Solar Project involved many useful items one of which was using a shopping list which saves time–Mother nature must be on your side or

you will face schedule implications

Having a great partner to lend a few hands and coffee made the project more pleasurable

04/13/23 Save energy and save money Today

4

Attention Areas

The glass face used on the Solar Heater project was salvaged from an old front storm door, LEXAN is an option – Planning a good couple of days or working

under cover is key to a good start

You will find this useful or perhaps entertaining if nothing else to making your own Solar Heater for Home, Garage, Shed, profit or other structures

04/13/23 Save energy and save money Today

5

Costs

Total cost of Project is less than $220.00 – All prices retail

If you prefer to modify this project go for it– Cost may increase– All items used for project were utilized

with as little waste as possible– Don’t be afraid to try this at home…

04/13/23 Save energy and save money Today

6

Technology

Small solar panel may be used to power an 80mm +6V/-12Vcomputer fan installed at top of 4” exhaust port used for draw

A DC thermostat may be connected to the solar panel for greater comfort– Summarize your needs on the project

This is a solar powered project which upon completion will not require any AC current therefore, saving valuable natural resources for the future

Recycled products will work!

Cut can as shown for heat spin

Next, stain your frame to protect it this is 1x6x10 cedar board

You may use other materials however, quality materials will out perform subpar materials

Make a secure setup for drilling the washed and cleaned cans

Next, use a ¾ inch metal bit to make a hole on bottom of can

Also, do not over tighten or risk damage to the thin cans design

Now you can see how the top differs from the bottom of can

Next, using your dimensions determine the size and cut out two manifolds and using a 2 ½” or 64mm hole saw make same number of holes in each to accept cans

Notice to remark your measurements for the 1” foil faced foam board and center.

Next, make sure you purchase 3 tubes of high heat sealant, you will need them to attach cans, insulation and glass or Lexan face to be used

As you can see, we used 1x4x8 pine strapping and made the sealed cans able to cure straight and strong, get a helper here

Notice, you will need 3 12oz.cans of flat black high heat spray paint for your aluminum cans and lining materials

Here, you must hang your cured cans on wire to be completely painted and dry prior to installation as well as inspection

Remember, to use same size cans and face

cans the same way for max efficiency

Below, dry fit your cut out dimensional lumber and cans

Here, you may now reinforce corners for longevity and make more measurements for the insulation material on all sides and bottom to be inserted

Assure all cans are preinstalled and facing the same way before you continue, careful of scratching paint

1” foil foam board is cut to install under cans snuggly

Here, you should precut all other foam board for insulating all the other cavities. dry fit them as well

Continue to dry fit for best results and remeasure dimensions while you can

Next, use a 4”hole saw bit and install (2) 4”galv. vent with tabs for output and intake manifolds, at the top and bottom use metal tape if needed

Using hole saw through the ¼” plywood may work better

Here, insert the 4”vent, bend back tabs and screw down just long enough to grab backing material and not puncture through

Next, use metal tape on all exposed foam board cuts, bending over edges for a finished look and good seal

Here, use high heat silicon sealant for attaching foam board and seal all gaps for max ratings and performance

We installed two 4”outdoor hinges to the top of the backing so that this Solar Heater

attaches to a Southern facing wall

Finally, it is coming together and all insulation is now taped and ready for aluminum flashing manifold covers

Cut Manifold covers to proper size using a utility knife and straight edge of wood to score and bend free

At the top of manifold a bowed piece of flashing is used to direct and channel heat out the top ductwork more effectively

Here, use high heat spray to touch up any exposed areas

Notice the screw holding the aluminum flashing arch with the 4” duct work for a secure fit and finish

Apply high heat caulking along entire edge of manifold and use weight to create good

seal with scrap wood to prevent scraping

Carefully paint flashing, edging and trim off excess sealant which will be seen under the face material used

The top manifold will get a fan and small hole for wiring to connect to a small solar panel

Now your ready for measuring, cutting and sealing the bottom manifold before spray painting

Here you may start solar panel and fan prep

Be prepared to cut part of the wire and clips from fan and solar collector for your project

Next prepare to measure and trim fan edges to fit inside 4” vent

Notice the 4” circle made on the paper which will be used as a template to trim down the fan for a perfect fit

Use a cutoff/grinding wheel or saw to trim the tough plastic corners

Here you will remove connector clips from solar panel

Next remove the molex connectors and yellow wire from your 80mm fan and strip back the red and black wires about 1”

Attach connector clips to ends of wire for easy future removal if replacement of fan is needed

Also place the fan into the top vent hole and feed both wires through small hole on vent housing. Be sure to point arrows on 80mm fan housing away from vent opening. Air flow must be directed out from the top exhaust vent

Sign your project before the top face is finalized and sealed

Here you may use aluminum stair edge for your

exterior trim and finish as it will secure the face

Be sure to seal all exposed areas

We used ¾” wood screws

Cut edging to size for your project

Next caulk exterior edging with generous amount of sealant and place face on top, once cured, install trim and screw down

Admire your efforts and reap the rewards from the sun forever.

Southern facing exposures are key as well as a clear path for sunlightHinges will attach to

South facing exterior wall with bottom vent as close to inside floor as possible for cold air to enter in.

The vent at top or bottom may be extended to reach a convenient inside wall area. The use of 2 registers with an open/close feature for comfort/control will do the trick

Measuring results with a brand new digital thermostat and the sensor inserted inside top vent

Notice the temperature of 149.3F and climbing

Here it is up to 152.6 and climbing

Notice the current air temperature is 94.3 F entering the bottom vent as well as the

included packaging material for proof

Finally notice the end result and vent temperature readings observed from the top exhaust vent, Wow…

Temperature readings taken outside show 94.3 F,10mph breezeand slightly overcast w/sun shine were present. Using a brand new digital thermometer to measure the heat exiting top and bottom vents of this Solar Heater demonstrate temps of 154.5 degrees F and climbing while using 94.3 F entering bottom vent. This is a 60.2 degree increase in temperature using free heat folks. Where else can you produce this increase without fossil fuel help?In addition, if the fan did not come on the heat from the Solar Heater will continue to exit the top vent regardless. Should the fan fail you may replace it easily due to connectors and placement inside top vent inside building being heated if you choose. Blocking the bottom and top vents should prevent overheating your selected area during the summer months or hot days which may not require additional heating.You will reap the rewards of your efforts and design for years to come by capturing and channeling heat created from recycled cans and sun light.We hope this convinces you and the skeptics of any doubts that could prevent your solar heater project of becoming reality and successful.

-Paul Cabral