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A Cape Dory 30C cutter rig gets a custom solar arch built from 1¼-inch polished 6463-grade anodized aluminum Schedule 40 pipe and Speed Rail fittings, replacing an undersized two-panel arch that blocked the wind vane blade.▶ 0:19 The new arch raises panel height by at least 10 inches to clear the wind vane and carries two 200-watt Buj RV N-type bifacial panels fixed on top and two 100-watt panels on sliding tracks below that retract for marina maneuvering and extend for maximum charging.▶ 1:14 The build is driven by a concurrent diesel-to-electric propulsion conversion that demands higher solar capacity.▶ 1:43 Two 23-foot lengths of pipe were sourced from a Jacksonville, Florida wholesale supplier at $135 each — cheaper than cut lengths ordered online.▶ 3:02 Speed Rail fittings required zinc-plated set screws replaced with stainless cone-tipped versions drilled into pilot holes for a secure grip; fiberglass leveling blocks with thickened epoxy bed the arch bases to the cambered deck; large backing plates spread the load below.▶ 9:50 Garhauer rail clamps lock the arch to the pushpit.▶ 11:54 Atom notes one design risk: the sliding lower panels are cut to close tolerances for the current Buj panel dimensions, so a discontinued panel size could strand a future owner without a direct replacement.▶ 15:00

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