The Collector

• 1). Lay the sheet metal down over the plywood and trim off any overlapping edges.
  
  
• 2). Using the wood molding, build a frame around the perimeter of the plywood. Secure this frame with wood screws so that it holds the sheet metal down over the plywood.
  
  
• 3). Cut a notch at the bottom left-hand corner of the frame and at the top right-hand corner. Make sure the notches are wide enough for the pipes going to and from your heater and that the radiator can fit through them.
  
  
• 4). Coat all of the surfaces of the collector that will receive solar exposure, including the sheet metal, with flat black spray paint.
  
  

The Radiator

• 1). Arrange the T-fittings into two rows of 32 so that the pipes can be attached between the rows. This means that the bottom parts of the Ts should be pointing at each other. Attach the T-fittings together in their rows using the PVC connectors.
  
  
• 2). Cap the topmost left-hand opening and the most bottom right-hand openings with PVC caps. You will notice that the outside openings of the arrangement now correspond with the notches cut in the collector's frame.
  
  
• 3). Carefully removes the ends from the fluorescent bulbs and paint the bulbs with the flat black spray paint.
  
  
• 4). Push each of the PVC pipes through the fluorescent bulbs so that they are sticking out from the bulb about 1/4-inch on both sides. Secure a pipe-bulb configuration between each pair of corresponding T-fittings. You should now have what looks like a radiator with its central pipes passing through fluorescent bulbs.
  
  
• 5). Wrap the T-fittings in aluminum duct tape and paint the entire radiator with flat black spray paint.
  
  

Assembly

• 1). Position the radiator inside the frame of the solar collector and secure it in place.
  
  
• 2). Mount the solar collector at a height parallel with the top of your water tank and angled toward the ground at about 35 degrees.
  
  
• 3). Run a cold-water pipe from the bottom of the water tank to the bottom left-hand opening of the radiator. Run an additional pipe from the top right-hand outflow of the radiator to the top of the water tank.
  
  
• 4). Secure the Plexiglas over the radiator and attach it to the solar collector's frame. Seal the edges around the Plexiglas with silicone caulk.