The On Deck Channel · video

What this video covers

Drilling and tapping aluminum solar panel frames to mount panels on deck brackets requires a 5/32-inch drill bit — the correct size for 10-24 machine screws — followed by a 10-24 tap to cut female threads directly into the panel's aluminum frame.0:49 Ryan demonstrates the process on double-walled panels, noting a scribe line on the panel edge that marks where the glass ends and defines a safe drilling zone covering at least 50% of the panel's side.1:03 The tap is run through both aluminum walls in sequence, eliminating the need for a nut on the back of the bolt, which is impractical with the deck brackets used.0:39 A standard machine screw (not a self-tapping screw) is then threaded into the tapped hole.1:44 Green Loctite is applied to each screw rather than Tef-Gel: green Loctite is weak enough to allow removal but strong enough to prevent vibration-induced loosening in high winds, and it also isolates the stainless screw from the aluminum frame to prevent galvanic corrosion.2:13 When tapping aluminum by hand is impractical due to volume, running the tap with a drill is a viable alternative.Watch

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