Sam Holmes Sailing · video

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Sam Holmes installs two 600-watt bifacial solar panels on a custom-built arch to increase the vessel's power capacity.12:38 He fabricates the support structure using PVC pipe reinforced with five to nine layers of fiberglass cloth and epoxy resin, utilizing peel ply for a smooth finish.0:55 The panels are wired to two 60-amp MPPT charge controllers.11:38 To improve visibility and ventilation, he modifies a polycarbonate windshield to swing inward using a palm router after a jigsaw failed to cut the material cleanly.13:57 Additional boat maintenance includes replacing the masthead light wiring, installing a new motor for the autopilot, and relocating the control panel to the helm using existing Raymarine mounting points.21:43 He also tests a battery-powered pressure washer and a rubber adhesive-removal wheel for deck maintenance.26:12 The project demonstrates that custom fiberglass supports can be fabricated using simple materials like PVC pipe and epoxy to create rigid, lightweight mounting structures for heavy solar arrays.

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