Build your own SOLAR FURNACE

Build your own SOLAR FURNACE

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CONTENTS Disclaimer... ii BUILD YOUR OWN SOLAR FURNACE... 2 Introduction... 2 Step 1: Cut Lumber & Spray Paint Soffit... 5 Step 2: Attach L-Brackets... 5 Step 3: Creating the Frame... 6 Step 4: Completing the Frame... 6 Step 5: Creating Exhaust Vent Holes... 6 Step 6: Attach Plywood to Frame... 7 Step 7: Attach Exhaust Vents... 7 Step 8: Insulate Your Solar Furnace... 8 Step 9: Cut Exhaust Vent Openings... 9 Step 10: Attach J-Molds... 9 Step 11: Attach Angled Spacers... 10 Step 12: Attach Aluminum Soffit... 10 Step 13: Adding Plexiglass... 11 Step 14: Install PVC Adjustable Vent Cover... 12 Step 15: Attach Dryer Vent Hose... 12 Step 16: Attach Exhaust Vent to Dryer Hose... 13 Step 17: Install Your Solar Furnace... 13 Index... 15 Notes... 16

BUILD YOUR OWN 1SOLAR FURNACE Introduction One of the cheapest ways to use solar power is with a solar air heater. Not only is it easy to build, it can also save you money on your utility bills. In this book, I ll show you how to create a window mounted solar air heater. They work by using a large collector to absorb the heat of the Sun. Black metal plates heat up and transfer warm air into your home through an open window. They work all winter long to help lower you heating bills. Just make sure to place the solar furnace on a south facing window that will get at least 5-6 hours of sunlight each day. That s it, let s get started. Create Your Own Solar Furnace what You ll Need: PArts 2Qty) of 1 x 6 x 8ft exterior grade stock lumber (1Qty) of 3/8 exterior plywood cut to 3ft x 5ft (1Qty) of 4ft x 6ft Sheet of Styrofoam insulation (vapor barrier backing with reflective foil surface) 2

(1Qty) of 10ft j-mold (1Qty) of 6ft j-mold (1Qty) of 10ft x 16 vented aluminum soffit (1Qty) of heat resistant matte black spray paint (1Qty) of 3ft x 5ft clear Plexiglass (1Qty) of 6ft x 4 x 4 angled metal/aluminum flashing. Cut to 4½ length pieces. (1Qty) of exterior caulking (4Qty) of 2 - L-brackets (10Qty) of 1½ deck screws (40Qty) of ¾ wood screws 3

what You ll Need: PArts (Continued) (30Qty) of ½ self-tapping metal screws (1Qty) a/c powered exhaust vent with thermostat (1Qty) of PVC adjustable vent cover (2Qty) of 4 round takeoff vent (1Qty) of 6ft-10ft dryer vent hose (1Qty) of Portable air conditioner window kit What You ll Need: TOOLS Cordless drill and bits Jigsaw Metal snips Caulking gun Tape measure Gloves Safety glasses Safety boots Utility knife Drywall knife 4

STEP 1: Cut Lumber & Spray Paint Soffit A: Cut Lumber Cut the 1 x6 x8 lumber down to 5ft so that you have 2 pieces (3ft length and 5ft length) Cut 2 off the 3ft piece so that you are left with a 34 piece. Do this for both 1 x6 x8 pieces. This is used to form a finished 3 x5 outside frame. B: Spray paint aluminum soffit Spray the upper surface of the aluminum soffit with heat resistant black paint (Do not use a gloss paint as matte finish will absorb more sunlight and heat) set aside to dry while you complete your box. STEP 2: Attach L-brackets Using the 5ft piece of wood, place L-bracket center and 1 from the end. Mark your holes and pre-drill ½ hole before using ¾ wood screws to attach L-bracket. Do this on the other end of the 5ft piece so the brackets are on the same side. Follow the same steps for the other 5ft piece. 5

STEP 3: Creating the Frame Join the 34 piece to the corner of the 5ft piece so that the L-bracket is touching both pieces. Make sure you are on a flat level surface. Mark your holes where the L-bracket will connect to the 34 piece. Pre-drill ½ hole before using ¾ wood screws to connect both pieces. Follow the same steps and connect all corners so that you are left with a finished frame. STEP 4: Completing the Frame For added strength, add 2 1½ deck screws to each corner. Before adding screws pre-drill 2 - ¾ holes. Use 1½ deck screws and screw into frame. In the end you will have placed 2 1½ deck screws on each corner totaling 8 screws in total. Now that your frame is complete, place your frame to the side. STEP 5: Creating Exhaust Vent Holes A: Exhaust vent hole 1 Using the plywood, measure 8 from center using the 3ft side. Make a mark. Now take one exhaust vent and measure the opening required for the vent to sit flush with plywood. Take those measurements and place a cut outline around your prior mark so that your prior mark is close to center of your outline cut. Take a jigsaw and cut out the opening. 6

B: Exhaust Vent Hole 2 On the opposite side of the plywood, pick any corner and measure in 8 and make a mark. Like in Step 6/ take one exhaust vent and measure the opening required for the vent to sit flush with plywood. Take those measurements and place a cut outline around your prior mark so that your prior mark is close to center of your outline cut. Take a jigsaw and cut out the opening. STEP 6: Attach Plywood to Frame Attach your plywood to your 3ft x 5ft frame using ¾ wood screws (12Qty) approximately 15-20 apart. Start by placing one in each corner. Make sure the 4 round exhaust spout is on the outside of the frame and that the flush side of the exhaust vent is in the inside of your frame. STEP 7: Attach Exhaust Vents Using ½ self-tapping metal screws attach both exhaust vents so that they are flush on one side, and the 4 round opening are both on the same side. 7

STEP 8: Insulate Your Solar Furnace Now with your outer frame complete, it s time to focus on the insulating your solar furnace. A: Add Styrofoam Insulation Base Cut to fit using a bladed knife, the Styrofoam insulation on to the plywood backer and attach using exterior caulking foil side up and vapor barrier side down against plywood. B: Add Styrofoam Insulation Sides Cut to fit, the Styrofoam for all 4 sides approximately 1 below the frame and attach with caulking. 8

STEP 9: Cut Exhaust Vent Openings Now that the inside frame is insulated, we need to cut out openings for the exhaust vents. Using a drywall saw cut the Styrofoam insulation through the 2 exhaust vents. STEP 10: Attach J-Molds Cut to fit and fasten the j-mold pieces to all four sides of the inside frame with self-tapping ½ screws. Make sure the j-molds sit firm on the insulation. 9

STEP 11: Attach Angled spacers A: Mark Angled Metal spacer Locations Place the 4 angled metal onto the Styrofoam insulation and score with a utility knife. There should be a minimum of 15 angled spacers inserted throughout to help trap the air from rising and giving time for it to be heated. Make sure all 4 angled metal spacers are pointing to the center exhaust vent at the top of the solar furnace. B: Push Angled Metal spacers into Position Using leather safety gloves push all angled metal spacers so that they are fully inserted into the Styrofoam insulation. STEP 12: Attach Aluminum Soffit A: Measure & Cut Aluminum Soffit Measure the inside dimensions of the j-molds. Cut to fit the aluminum soffit with metal snips so that it will slide inside the j-molds and rest on the angled metal. You will need to cut two separate pieces of the aluminum soffit that you will later attach together. 10

B: Attach Aluminum Soffit Pieces Insert both pieces of aluminum soffit so they are overlapping and inside the j-mold. Attach the two aluminum soffit pieces together with (3Qty) ½ self-tapping screws. STEP 13: Adding Plexiglass A: Pre-Drill Plexiglass holes Place the Plexiglass in its exact location so that it covers the entire box end to end. Pre-drill 10 holes, ½ deep around the outside edges through the Plexiglass and the wood frame. B: Apply Caulking to Plexigass Apply a 1/8 bead of caulking to the upper edge of the frame and with a helper, carefully place the glass back to the exact location. 11

C: Attach Plexiglass to frame Fasten the glass through the pre-drilled holes using ¾ wood screws (be careful not to over tighten) wipe off any residual caulking and allow to dry overnight. STEP 14: Install PVC Adjustable Vent Cover Install PVC adjustable vent cover on intake hole. This is the one located in the bottom corner of your solar furnace. STEP 15: Attach Dryer Vent Hose Attach dryer vent hose to other opening located at the top of your solar furnace. Attach with a dryer vent clamp. Feel free to use foil tape to ensure a tight seal. 12

STEP 16: Attach Exhaust vent to Dryer hose Attach exhaust vent to end of dryer hose. Attach with a dryer vent clamp. Feel free to use foil tape to ensure a tight seal. STEP 17: Install Your Solar Furnace Your solar furnace unit is now complete and ready to install to your desired location. A: Find Install Location Location of your solar furnace should be close to a window that has an electrical socket inside your home nearby (you will need to access it later). You may use a vertical sliding window or a horizontal sliding window. Make sure your solar furnace is free from any obstacles so that it has full view of the sun. B: Install Exhaust vent in window frame Once you have located the desired window; you will install the exhaust vent at the end of the dryer hose into the window opening. If you have a two pane window you can place the exhaust vent in the window opening and close one window pane to hold the exhaust vent in place. Then cut to fit a piece of styrofoam insulation for the remaining window opening. Close the second window pane to hold the insulation in place. Finally you will need to use some foil tape to insure the window is insulated properly. 13

C: Finish Connection & Set Temperature The final step is to place your powered exhaust vent with thermostat into the exhaust vent hole located on the inside of your window. Plug it in and set your desired temperature. The thermostat will regulate the amount of heat entering the room and with its built in fan; it will draw the heat created by the solar furnace. Now that you ve finished your Solar Furnace installation, you can sit back and wait for the savings to come in. Not only will you be saving money on your heating bill, you will also be helping save the environment. David Bradley with his completed Solar Furnace installation. 14

index A adjustable vent cover 4, 12 air conditioner window kit 4 aluminum flashing 3 attach aluminum soffit v, 10, 11 attach exhaust vent 13 C caulking 3, 8, 11, 12 creating the frame v, 6 D dryer vent hose 4, 12 drywall knife 4 E environment 14 F finish connection 14 H heating bill 14 heat resistant black paint 5 I install PVC adjustable vent cover 12 insulate solar furnace v, 8 insulation 2, 8, 9, 13 J jigsaw 4 j-mold 3, 9, 11 L lumber 2, 5 M metal snips 4 N notes 16 P plexiglass v, 3, 11, 12 plywood 2, 6, 7, 8 S set temperature 14 solar air heater 2 solar furnace v, 2, 8, 13, 14 T thermostat 4, 14 V vent 4, 6, 7, 10, 12, 13, 14 W wood screws 3, 5, 6, 7, 12 15 INDEX

NOTES: 16