Materials needed:

• 2 x 850mm extrusion

• 3 x 385mm extrusion 

• 1 x 450mm extrusion (no holes)

• 4 x corner plate

• 2 x angle bracket

• 2 x T-plate

Tools needed: 

• 4mm hex wrench

Instructions:

1. Locate the pieces of aluminum extrusion. Lay them out to “dry fit” them as shown. If you have already built the frame before the cart has been assembled, simply lay the frame onto the cart and make sure it fits. If not, gently loosen the T-nuts, re-align the extrusion pieces, and re-tighten as needed.

2. Locate the corner plates. Make sure the T-nuts are loose but not removed. Carefully position them into the tracks of the extrusion and align everything so that it is square. Gently tighten each bolt, but do not overtighten them. Hint: If you tighten it slowly, you should feel it “catch” as it self-aligns in the slot. If you tighten too fast, or if you do not loosen enough before tightening, it may turn and become parallel to the slot. This is not good, as it won’t bridge across the slot and hold. To fix this, simply loosen the T-nut and try to tighten it again.

3. Attach an angle bracket to each of the captive slot nuts. Keep them loose enough to slide for now

4. Add the upright stand (550mm) by sliding it onto the captive slot nuts of the angle brackets. Do not fully tighten it yet. Align it so that it is in the middle of the base. Now, you can tighten each nut. Hint: You don’t need to tighten it as hard as you can… Just make it snug. Overtightening can damage the material.

Materials needed:

• 1 x 90mm extrusion (shortest)

• 2 x T-plate

• 2 x “B” hinge

• 1 x 3090 x 450mm extrusion (black)

Tools needed:

• 4mm hex wrench

• 5mm hex wrench

Instructions:

1. Locate the 90mm extrusion and 2 T-plates. Attach the T-plates on each side as shown.

2. Locate the “B” hinge set. Attach the pivot as shown. Make sure to pay close attention here. Notice which half of the hinge is connected and how it is facing. Make sure that the bolt head will be facing outward to make it easier to assemble in future steps

3. Your finished pivot head should look like this

4. Attach the other half of the pivots to the 3090 extrusion. Try to find the best position and tightness so that everything lines up and moves easily. This may take some patience and practice loosening and aligning the parts together before you tighten them down. Adjust as needed as you work. Don’t overtighten bolts, or the pivot won’t move. Check it to make sure it looks and feels good before you move on to the next step

Materials needed:

• 6” linear motor

• 2 x motor fasteners

Tools needed:

• 4mm hex wrench

Instructions:

1. Using the included mounts with the motor, attach only the “bottom” part of the 6” motor using motor fasteners (you’ll need to slide these down from the top of the upright stand). Note: This picture is for reference only, you finish mounting the motor and other pieces in later steps.

Materials needed:

• 1 x solar panel

• 2 x  450mm extrusion (with holes)

• 4 x Bolts with flange nut

Tools needed: 

• 4mm hex wrench

Instructions:

1. Lay the solar panel cell side down on something gentle, like a flat table or on the cardboard box it came in. Be careful, as the solar cells are important. This is how you get electricity from sunlight! Rotate the solar panel so that the wiring is coming from the right side as you look down at it from above. Locate the long bolt with a flange nut. Loosely attach them in the two pre-drilled locations on the solar panel.

2. Slide the extrusion through the head of the bolt. This will seem a little backward, but the head of the bold will hold in the slot, then use the drilled hole to insert your hex wrench and snug the head of the bolts. You may need to hold the flange nut on the backside with your fingers. However, you should not need to use any tools on the flange nut. Just snug these bolts enough to keep the parts together. Remember, overtightening can damage the materials

3. Use the 4mm hex wrench to gently snug the bolts. (Not your wrench is L-shaped, so this step may look slightly different)

Materials needed:

• 2 x “A” hinge

Tools needed:

• 4mm hex wrench

• 5mm hex wrench

Instructions:

1. Locate hinge set A. Attach them as shown on the 3090 and solar panel frame. Pay attention to the pre-attached T-plate. This should be “up” if the solar panel frame connections are on the right (as shown). Make sure the bolt head is facing toward the outside so that you can access it with the tool. Try to find the best position and tightness so that everything lines up and moves easily. This may take some patience and practice loosening and aligning the parts together before you tighten them down. Adjust as needed as you work. Don’t overtighten bolts, or the pivot won’t move. Check it to make sure it looks and feels good before you move on to the next step.

2. Working with a few partners to carefully mount the solar panel (which can not pivot) onto the upright (which can also pivot!). Right now, everything is loose. Be careful as you work with it so that you don’t pinch your fingers or swing the panel around (it could crash).

Attach the shorter of the two linear motors to the front of the upright strut using the provided mounting brackets. Very important: With the motor fully retracted, mount it so that there is a noticeable angle between the upright and the linear actuator. You don’t want it to return to true vertical position, or you might damage the motor or circuit. Don’t forget the cotter pin to keep the motor connected to the mount!

Materials needed:

• 1 x 550mm extrusion

• 1 x angle bracket

• 8” linear motor

Tools needed:

• 4mm hex wrench

Instructions:

1. Slide an angle bracket onto the 3090 (captive nut) and slide the azimuth motor strut piece (450 mm extrusion) into the T-bracket.

2. Put the mounting brackets on the motor. Mount the 8” linear motor using motor fasteners. Don’t forget the cotter pin to keep the motor connected to the mount!