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Step 3Build the collector
1. 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.
2. 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.
3. 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.
4. 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.
5. 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.
6. 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.
7. 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.
8. 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.
9. Repeat the dry fit on the end of the corrugated plastic sheet. Carve up the ABS as needed to get a nice fit everywhere.
10. After everything fits nicely, repeat the assembly, applying silicone adhesive to all mating surfaces before assembly, and applying a bead of silicone to all seams after assembly.
11. Repeat for the other end of the corrugated plastic.
12. Allow to dry for at least 24 hours.
13. After drying, cut the garden hose in half and clamp the cut ends to the nipples.
14. Fill the panel with water (just connect the garden hose to a tap on your house) and check for leaks.
15. If there are any leaks, drain the panel, dry the area around the leak thoroughly and seal with more silicone adhesive, allowing another 24 hours to dry.
16. If you are interested in calculating the efficiency of your collector later, you need to know its volume. This is a good time to drain it into a bucket and measure the volume (including the hoses). Mine contained 7.2 litres.
17. Once any leaks have been sealed, paint the surface of the collector black and set it somewhere to dry.
2. 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.
3. 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.
4. 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.
5. 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.
6. 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.
7. 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.
8. 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.
9. Repeat the dry fit on the end of the corrugated plastic sheet. Carve up the ABS as needed to get a nice fit everywhere.
10. After everything fits nicely, repeat the assembly, applying silicone adhesive to all mating surfaces before assembly, and applying a bead of silicone to all seams after assembly.
11. Repeat for the other end of the corrugated plastic.
12. Allow to dry for at least 24 hours.
13. After drying, cut the garden hose in half and clamp the cut ends to the nipples.
14. Fill the panel with water (just connect the garden hose to a tap on your house) and check for leaks.
15. If there are any leaks, drain the panel, dry the area around the leak thoroughly and seal with more silicone adhesive, allowing another 24 hours to dry.
16. If you are interested in calculating the efficiency of your collector later, you need to know its volume. This is a good time to drain it into a bucket and measure the volume (including the hoses). Mine contained 7.2 litres.
17. Once any leaks have been sealed, paint the surface of the collector black and set it somewhere to dry.
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Jun 28, 2009. 7:41 PMadrian.ccs
says:
Hi iwilltry, thanks for the guide but one question, is the corrugated panel double so that water pass right through it??? or how does this work?
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Jul 6, 2009. 11:30 AM
iwilltry (author)
says:
iwilltry (author)
says:
The corrugated panel has square channels that run through it so water can pass right through.
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