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The crew upgrades their boat's solar capacity by replacing a 180-watt panel with a 440-watt unit, necessitating a significant extension of the existing stainless steel solar arch.1:27 To prevent galvanic corrosion between the aluminum panel frame and the stainless steel mounting structure, they apply Gorilla tape as a barrier.12:41 Initial fabrication attempts result in excessive structural wobble, which they resolve by welding additional diagonal stainless steel bracing bars to the arch.26:38 The project requires two weeks of labor, including rerouting electrical cables and installing a new charge controller.27:11 Despite the structural challenges, the system successfully delivers 29 amps of charging current upon completion.27:39 The installation highlights the necessity of rigid bracing for large solar arrays on offshore vessels to prevent metal fatigue and structural failure.26:38

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