Sailing Catalpa · video

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Lee and Sarah upgrade the solar array on their center-cockpit sailboat, Catalpa, by replacing a deteriorating canvas bimini with a rigid, custom-built hardtop.4:44 The project increases their total solar capacity from 1,440 watts to 2,400 watts using 12 new 200-watt Renogy solar panels.14:12 To manage shading from the mast and rigging, the crew selects these panels for their improved shade management and diode configuration.3:38 Lee constructs the support frame using existing tracks and aluminum tubing, reinforcing the joints with spot welds to prevent the structure from pulling apart under load.6:39 To ensure the hardtop remains watertight, the crew fills the four-millimeter gaps between panels with foam backer rod before applying TotalBoat sealant.11:38 During installation, an initial attempt to wire three panels in series triggered an over-current error on their 150-volt Victron controller, forcing a switch to a parallel wiring configuration.9:19 The new setup provides a 70% increase in power generation, allowing for greater energy independence while preparing for a Pacific crossing.14:33

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