Step 4: Building the Solar Rack

The finished vehicle with have an overhead rack to support the solar panels. The rack has to be high enough to let the child in and out without hitting their head. The finished solar canopy will also shade the driver, nice for keeping cool in the summer!

The top of the rack needs to be a size to match the solar panels, while the bottom of the rack needs to line up with solid points on the frame of the vehicle.

To start with measure the frame of the vehicle. You may need to remove the plastic body, or at least disconnect it and pull it partially up to get access to the frame. The Jeep has easily accessible push-nuts that hold the body on.

Once you have identified the length and width of where the solar rack with attach to the vehicle frame, write it down.

Drill holes through the plastic body (5/8" spade blade worked well) directly above where the rack will connect.

Next, measure the size of the solar panels, particularly noting any holes or slots that are used as attachment points. You will want the conduit to line up with those points so that the rack holds up the PV panels, but also allows for a bolt or screw from the panels, through the frame to secure it in place.

Depending on your car and solar panels, your rack may be an odd shape, like an old-fashioned football goal-post, a ladder, or some shape other than a rectangle. That's OK, as long as the top fits the solar panels, and the bottom fits the POWER WHEELS.

Cut 1/2" electric conduit to the correct length to build the top portion, which will fit the solar panels. I found that a plumbing pipe-cutter works really well to cut 1/2" conduit. It's safer and quieter than power tools, and leaves a very clean cut that really doesn't require any other filing or finishing.

Weld the conduit together, and lay your solar panels on top to confirm that they fit correctly.

Now you will want to measure how TALL your rack is. You may want to get your little tyke out to the car and see how much room they need to get in and out of the car, allowing plenty of room so they don't bump their head. Remember to leave room for them to grow taller!

Cut four pieces of conduit to the height you chose.

Weld the conduit to solar rack, with the rack laying on the ground, and the "uprights" straight up from it. Flip the rack over and it should look roughly like a pickup truck ladder rack.

Grind down any bad welds, fill in any holes, and then paint the rack. I like Rustoleum Gloss Black spray paint. It always looks nice, seems to hide bad welds, and in this case, matches the trim and tires on the Jeep.

<p>Awesome !! What is the top speed/range?</p>
<p>Couple questions (I apologize if you answered them and I missed them): 1) how long does it take to fully charge the battery, and 2) how long does the battery stay charged (if not in the sun)? My boys want to make one for an indoor competition. Thanks so much - Stacy</p>
<p>Hello Ben I came across you video while researching an idea for an agriculture project. Great build first of all!! I know this was three years ago but the Lord just recently gave me an idea for a project using a solar powered Power wheels motor and frame for our youth agriculture program. I would like to know if everything worked out for the long haul like you wanted and what would you do differently. Man this is a fantastic idea did you ever consider patenting it and selling to Hasbro as an add on? or doing retro fits?</p><p>with the panels and frame charge controller etc what was you total cost? Its a blessing you were able to weld it and do all the work your self. Once again great job very innovative!</p><p> I would love to hear from you thanks Minister Drew from Camp CARVER <a href="mailto:themightymen@hotmail.com" rel="nofollow">themightymen@hotmail.com</a></p>
That is sick!!!! Although it would be even more awesome if you made it gas powered!!!
Hi everyone, <br> <br>After thinking about it for a while, I think I could build a version of this entirely out of plywood and stock electronic parts from scratch. <br> <br>It could be sold as a kit. (Precut wood parts flat-packed, with with electric motor, and a few other required parts.) <br> <br>What would you think of that?
Awesome! And I love the sheep in the jeep, so cute :)
Excellent build as ever ben!
this is a FANTASTIC idea !
Isn't it good when you can combine your hobbies with things your kids like to do? I find it's a lot easier to get build time when &quot;it's for the kids&quot;. Really nice build - reminds me that I need to learn how to weld.
Great job!! What is the top speed/ range? <br>
5 miles per hour<br>One backyard ( I guess that generally Power Wheels are considered an hour or so run-time )<br><br>My little girl usually plays with the car for up to 20 minutes, and the battery is fine for the whole time she's playing.
I LOVE IT! Very well done. <br> <br>I'm not sure what I loved more in the video... You riding it, or the comment about you having to teach her about the brakes! lol ;-)

About This Instructable




Bio: Ordinary guy with no special skills, just trying to change the world one backyard invention at a time. See more at: http://300mpg.org/ On ... More »
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