Here’s the finished heater with glass installed and trim (I’m going to treat the trim and support boards with the same color stain/water seal as the d...
I made this solar-powered swimming pool heater out of common materials anyone could get, with ordinary tools most average homeowners have (or can borrow from friends). A friend of mine named Ace gave me a sliding glass door that was going to be thrown out from a job site he was working on (he's a roofer, and the door had some minor cosmetic damages to the metal frame).
I decided to make it out of pressure treated 2�4s and 3/43 plywood - the glass had leaned against my studio for over a year and you can see weeds and the weather had them filthy (wow I need to pressure wash my siding):
Step 2: Sizing the box
So the size of the collector box was dictated by the glass size (76″ x 46″). Here’s my little helper buddy Muggy (my 6 year old son) helping me lay out the copper fittings - he was a big help throughout the entire project :) . Also you can see part of my German Shepherd Hoppy - she was NOT a big help:
Step 3: Copper flashing backing plate
I ordered a 102 x 203 roll of heavy copper flashing .0216 (standard heavy weight for larger craft work, roofing and range hoods etc.) from Storm Copper Components - they are great, lowest price I could find and when I unrolled it it was almost 63 longer than 102 :
Step 4: Manifold and backing plate
I cut it in half and laid the two sheets under the copper manifold I made from 1/23 copper tubing I got from Lowes (the total copper cost in this project was around $250.00):
Step 5: Soldering the manifold to the backing plate
Then I had a hard time soldering the tubing to the flashing, the heat tended to make the flashing buckle - I screwed the tubing down tight to the flashing with metal strapping, and just did as much as I could - skipping spots when the gap got over 1/8 of an inch or so. Still I made contact with around 70% of the tubing I think: