The Bug has two new forward solar panels, and now it has deflector shields to protect them from flying debris.
Forward Shields are up, Sir!
The Bug originally had two solar panels. After some time it became apparent it would be worth adding two more, so that's what I did. (If you missed The Bug project, there's the link.)
Even before they were installed I started worrying about how exposed the forward edge of those new panels would be. I could just see them getting damaged by the impact of some flying foreign object. So another rabbit had jumped out of its hole right in front of me and I had to chase it down.
I chose all aluminum and stainless steel materials for the new Deflector Shields. I made brackets from 1/8" thick flat stock and angle stock, and used a nice thick diamond plate for the shields.
I've never actually made anything from nice thick sheet aluminum before. My inexperience became apparent when I failed twice to cut it using 1) a jigsaw with a metal blade and 2) an angle grinder with a diamond wheel.
The jigsaw kept veering off the line even though I had a guide for the saw. Very frustrating.
The angle grinder's wheel became clogged with molten aluminum, which came as no real surprise.
Another trip to Lowe's and a $46.00 circular saw blade made for cutting aluminum, and I finally got a good cut.
I had fun creating a way to make a smooth bend along the long axis of the shields. Once again Unistrut proves its worth. Unistrut is my friend.
The rest of the construction was pretty uneventful. Measure, cut, bend, drill, attach. The result is solid and feels very permanent.
Deflector Shields Gallery
Bug's new Forward Solar Array Deflector Shields are certainly Things That Work.
