steel as a frame material

[wooky1971]

Im sorry for posting this if its been answered. I did do several searchs before I asked.

I have access to light weight angle iron that is the same size needed for solar panels. It costs me nothing. I can only think of two reasons to use aluminum. Weight and it dosent rust. Im always making something out of this stuff so I have welder, chopsaw, drill press, etc. If i put a good coat of paint on it to keep it from rusting would it work for solar panels?

[Sunking]

The only kind of paint that is going to hold up on iron out in the weather is an enamel powder coat.

[john p]

Even powder coated enamel will fail after a few years . its First failure point will nearly always be the bolt holes, and the cancer will spread from there. No matter how well you clean the steel before painting moisture willl find some inperfection and the paint will lift.

[Sunking]

I agree John, the point is powder coat is the best for iron. But like you said it will fail.

[wooky1971]

Well after reading some of the comments on the diy solar panels I have come to the conclusion that and diy panels I will make will power sheds and outbuildings. I will watch for good deals on UL rated panels for the main house. The diy panels will be something to put some power in places that currently dont have any. I will mount them on a steel pole out in the open. One other use for doing the diy panels will be to get a better working knowledge of solar setups. Maybe that way I can cut costs by doing as much installation of my main house setup myself. I have had electricians let me drill studs and pull my own cable and just leave the final connections for them to cut on labor costs. I have a gentleman that lives close to me that has a nice 8 kwh system that was professionally installed that I can look at for an example. So basically the diy panels will not be for a long term anyway.

[russ]

If you check carefully on the net you can find factory panels cheaper than you can make DIY panels - with guarantees

[john p]

SUNKING to be technically correct enamel powrder coating is not the best, The best by far is red lead paint.. BUT it is not legal in most countries to use it. Its been off the market in Australia for about 40 years , You would know how long in USA .
But because the Philippines is so enviromentally concious it is still available there. I painted some steel work around the house about 9 years ago and its still perfect,and we live only about 100 meters from the ocean.

[Mike90250]

Hot dip galvi, after holes and cuts have been made, is pretty darn good. I always wonder about the aluminum panel frames that have been anodized (good) then cut and drilled (bad) with all the raw edges exposed....

[john p]

True hot dip galvanizing is good if every hole is done beforehand and good clearance around the bolt holes and galvanized nuts bolts and washers are used. But the cost of getting the frames galvanized is likely to take to cost to close what aluminium frames cost..

[axis11]

Angle bars made of steel with a good coating of epoxy primer will last longer than the life of the cells in a DIY panel. Since you dont have to buy the steel frames, it will be a good match for a diy panel. If you dont have the cells yet, just buy ready made panels.

[john p]

Angle bars made of steel with a good coating of epoxy primer will last longer than the life of the cells in a DIY panel.This is more likely true than not true

[axis11]

Angle bars made of steel with a good coating of epoxy primer will last longer than the life of the cells in a DIY panel.This is more likely true than not true

You're right, there are a few exceptions. Those using good encapsulants like EVA and Sylgard combined with a good worksmanship could outlast the steel angles.