Off-the-Grid Solar Wagon : 7 Steps

The Solar Wagon can be used as a portable or emergency energy system to charge laptops, cell phones, LED lights, or computer speakers. It is made from a re-purposed garden cart with a custom-built solar panel frame and off-the-grid solar electronics shelf. The project budget ranges from $500-$1500 depending on the materials, tools and solar components that you buy or might already have. If you have not welded or worked on solar electronics before, take a class or collaborate on this project for best results.

For more info on our Solar Charging Station projects and workshops see:
www.SolDesignLab.com
www.facebook.com/soldesignlab
info@soldesignlab.com

Step 1: Getting Started

Collect all the tools and materials needed for this project.

Build a frame on top of a sturdy steel garden cart to hold the solar panel and electronics (bolt or weld together).

Extra: waterproof the electronics box, make the wagon lockable, add graphics, add a bike hitch.

Material Supply Options

www.altestore.com (off-the-grid solar components) http://www.altestore.com/learn/ (resources)
Check out the alt E store system calculator: http://www.altestore.com/store/calculators/off_grid_calculator/
Local Steel / Electrical Supply
Little Giant Wagon (globalindustrial.com) or try and InStep bike trailer
“Photovoltaic Design and Installation Manual”

Step 2: Wagon Frame

Select a small but sturdy cart with 4 wheels. Consider if you will need to take it apart for transport or storage.
Measure and prepare the wagon for the solar frame.
Measure and cut the flat bar / angle iron steel /aluminum frame parts to fit your wagon and solar panel.
Make sure the angle of the solar panel is your location's latitude (37° in San Francisco).
Tools (drill, band saw, welder, grinder, wire strippers, screwdriver, wire crimpers).
Paint wagon with an outdoor metal paint (Rust-o-leum).
Hardware (1/4-20 1"-2" machine screws, lock washers, bolts).
Bolt the frame to the wagon and then bolt the solar panel on top.

Step 3: Electronics Panel / Frame

Measure and cut the steel /aluminum frame parts to fit your wagon and solar electronics board.
Weld / bolt frame together with 1” angle.
Use 16 gauge perf. steel /aluminum sheet for electronics wall.
Add holes to bottom of legs to bolt to wagon floor in 4 places.
Use webbing straps to secure the battery -- to the wagon floor.

Step 4: Solar Components

60 Watt Solar Panel (20-60 watts are best)
12 Volt 35 AMH Sealed AGM Battery
USB outdoor socket
Sun Saver MPPT 15 Amp charge controller
Sun Saver 300 Watt inverter
Morningstar Sun Saver remote meter
Breakers / bus bar for the solar panel, battery, and inverter (load)
LEDs
Label maker (label - / + wires)
Black and Red wire

*Wire the electronics with the help of a solar electrician or take a solar class
*Review battery safety steps

Step 5: How to Use the Solar Wagon

Add custom solar info graphics to attract attention and share information on solar.
Make sure the wagon is facing South in the direct sun when charging up the battery and that the breakers are switched on.
Use a bike lock to keep the wagon secure while charging.
Keep the Solar Wagon in a clean dry area when inside.
Turn the breakers off when not in use. (Do not drain the battery)
Do not leave in the rain without water-proofing the electronics.
Bring it to a picnic or event to play music and charge cellphones!
Use during power outages.