Making Solar Panel mounts, what thickness angle iron?

DAS26miles wrote:
I am going to make my own solar panel mounts using 2 aluminum 1 1.2" or 2" angle iron. Do I need the heavy 1/8" or will the thinner do? Reason I am asking is I will need to cut them to size and the upper portion may need to be ripped so as to keep the panel height down to 1 1/4 to
1 1/2". And I will be using a table saw if I need to rip or my 10" compound mitre saw wit 60 carbide teeth. It's an old blade and needs to be replaced anyway.

Little bit of a contradiction there. It's aluminum extruded angle, not aluminum angle iron, 2 different things and when you cut it, put the blade in backwards. In correct, dull or not, it will grab your angle and make a mess or injure you and we don't want that.

Better yet, use an hand hacksaw, much safer.

Here is what I made for mine they are 1/8" thick 1 1/2" angle and 1 1/2" flat stock

Not sure if your brackets are similar setup to mine...but with a 2"bracket you can decide where your bolt goes through the side of panel and adjust standoff height as required. Heres a pic of a similar setup to mine.

https://www.google.ca/search?biw=1366&bih=637&tbm=isch&sa=1&ei=SKMmWv_yHoKejwPgroSIDg&q=aluminum+l+brackets+for+solar+panels&oq=aluminum+l+brackets+for+solar+panels&gs_l=psy-ab.3...36060.38521.0.39198.17.17.0.0.0.0.126.1555.11j5.16.0....0...1c.1.64.psy-ab..1.1.105...0i30k1j0i24k1.0.WKdnh5AiBKM#imgrc=KaFUjEK_T0lx2M:

Aluminum with Aluminum. Otherwise, you set up galvanic corrosion unless you isolate the contact points.

The 1 1/2" x 1 1/2" angle irons would give me a 1 1/2" gap under the panel to the roof. I don't see how I can get it down any lower. The 2"x 2" would be worse with 2" underneath unless I rip the angle iron attached to the panel down to 1 1/2" or 1 1/4" but need to leave enough space for the bolt.
Note that the 1 1/2" angle iron is not wide enough to accommodate the panel bolt that's why a 2" angle iron cut down on one side to 1 1/2" or 1 1/4" would be better.

I would for sure go with 1/8" aluminum and 2" x 2" stock. Remember to keep some airspace between the panel and the roof so anything shorter might see your panel physically touching the roof membrane. If the "L" stock is bolted onto the side of the panel its likely going to leave you with 1/4" or a bit more gap and flush with the top of the panel on the side depending on brand. That should work out about right.

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I'd use 1/8 thick. 1/16 might bend too easy and I wouldn't want to rely on anything that thin holding wings to the roof at highway speeds.

You might check with onlinemetals.com they may have the height and width you need and there is no minimum length or amount for orders.