The past few weeks I've been working on adding solar to keep the battery charged and switching over my running lights to LED. It took longer than it should have but this is a first for me and was a bit more complicated than I expected.
The LED switch over was easy, although I did run into a small oops. When I switched the stern light to LED everything was great. However, after I swapped out the old bulbs for the new LED ones put everything back together and flipped the switch nothing happened. My immediate thought was I broke an old connection when I pulled the bulbs since they were a bit stuck.
Luckily that wasn't the case. After taking about the port and starboard bow lights I discovered that I had inserted the LEDs wrong. I wasn't paying attention and inserted the LEDs with the positive and negative lined up incorrectly. With the positive and negative lined up correctly I inserted the LED and proceeded to temporarily blind myself. I forgot to mention that at this point the sun was setting so things were getting dark, and I had left the bow lights powered on. Once my vision returned, I reassembled the Starboard light and did my best to not blind myself with the Port light. With everything back together and working that another item off the checklist.
If only the solar panel had been that easy. I blame my inexperience for the stumbles I experienced. I watched a lot of videos on adding solar to boats, I checked out some solar setups on boats at the marina I am in, and I spoke to a good friend who had just gone through this. Of course, before I did all this, I ordered a 50-watt panel with a controller off Amazon during Prime Days because it was 50% off.
I wanted to go with a rail mount setup. Some people opt for Deck mount but that's just something else to get in the way. Now it seems there are 2 main ways to mount a panel to the rail. Both options use rail mount brackets, there are a number of brackets that can be used but they fall into 2 types, easily removable, and less easy. I opted to go with the easily removable so I could make adjustments, remove it for winter storage, and not having to risk losing another tool to the murky depths of the lake.
Now the first option is to mount the rail bracket directly to the solar panel and then to the rail. Of course, using this option was not possible for me for a few reasons. The first being the frame of the solar panel was not wide enough for the rail mount bracket to feel secure. The second reason is that I'm not sure I could find a screw and nut combination short enough to fit, but honestly, I didn't look after reason 1.
The second option to mount the bracket to the panel is to take two pieces of aluminum flat bar wide enough for the brackets and long enough to span the back of the panel. This is the method I went with, not only did the bracket make complete contact with the flat bar but it also allowed me to get the bracket attached securely using some loctite orange for a bit of extra piece of mind.
The first step was to determine what orientation I wanted the panel in since it's a rectangle. I decided to go with having the long side run horizontally, I felt it would just look better. Once this was determined I measured the width of the panel, doubled it and then purchased the length of aluminum flat bar. I went with Aluminum because the panel frame was Aluminum, it's light weight, and inexpensive, like less than $20 with enough left over to do a second panel.
With the flat bar purchased I cut it to length using a hack saw, drilled 2 holes in each end and mounted it to the panel. Simple right, wrong. First off despite drawing a straight line using a framing square, cutting slowly I still somehow managed to cut at a slight angle. Second, despite what you might read or be told, a nail set does not, I repeat, does not work as well as a centre punch. After 2 holes drill slightly off, I headed out and purchased a centre punch.

Getting ready to drill the first of 8 holes
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The next step was to drill the holes in the solar panel frame. Luckily the panel came with holes about 3 inches out from each corner on every side. With these holes I just needed to drill 4 holes. Since I couldn't use the centre punch on the panels, I mounted the flat bars using the existing holes in the panel frame and then used the holes in the flat bar as a guide for the drill bit. Being very careful to not punch through and hit the back of the solar cells I successfully drilled the 4 holes.

A cedar shim was the perfect thickness to support the panel frame while drilling
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The flat bars mounted to the panel
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Next up was mounting the rail backets to the flat bar. I measured, measured again and laid out where the brackets would go.
I then removed the flat bar from the panel, used the center punch to mark the holes and drilled 2 holes near the centre of each flat bar. With the holes drilled I mounted the rail brackets to the flat bars and then attached the flat bars to the panel.
The last step was to mount the panel on the rail, connect it to the controller and then the battery. Currently the battery lives in the port cockpit coffin. I am not sure if that is where I will keep it so the wiring is temporary.
The backside finished and mounted
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Looking sharp I think
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