Array top cap
2" Pipe Array Top Cap
- Fits 2" (2 3/8" OD) ground pipe
- Build arrays from 1 to dozens of panels
- Set bolts + two 3/8" U-bolts for the pipes included
Free guide
How to Build an Off Grid Solar Array on Pipe Poles
A plain-language, step-by-step guide to building a DIY ground-mounted solar array with galvanized pipe and bolt-on top caps.
You don't need a welder or a custom fabricator to build a solid ground-mounted solar array. With standard galvanized pipe from a hardware store and a set of bolt-on top caps, you can put up an array of almost any size in a weekend. Here's the plain-language version of how we do it.
1. Decide how big your array will be
Start with how many panels you want and how big they are. That tells you how many poles you need.
- 1-6 panels: a single pole with a top of pole mount is usually simplest.
- More panels: use array top caps on 2-20 poles with cross pipe between them.
2. Gather your parts
Almost everything comes from your local hardware or big box store.
| Part | What to get |
|---|---|
| Ground pipe | 2" (2 3/8" OD) or 2.5" (2 7/8" OD) galvanized schedule 40/80 or oilfield pipe, one per pole |
| Cross pipe | 2" (2 3/8" OD) pipe for the horizontal rows |
| Top caps | One per ground pipe, sized to your ground pipe |
| Panel rails | Unistrut or aluminum rails to attach panels to the cross pipe |
| Concrete | Enough to set each ground pipe |
| Tools | Level, tape measure, string line, post-hole digger or auger, wrenches |
3. Lay out and set your poles
Pick a sunny, open spot facing south (in the northern hemisphere) with no shade from trees or buildings for most of the day. Run a string line, mark each pole position, and dig your holes. Set each ground pipe plumb in concrete and keep the tops level with each other. Check local codes for hole depth and any permit requirements.
Tip: set the poles a little tall and cut them level after the concrete cures. It is much easier than getting every pole perfect in wet concrete.
4. Bolt on the top caps
Once the concrete has cured, drop a top cap on each pole and tighten the two set bolts. No welding or drilling needed.
5. Run the cross pipe
Lay the 2" cross pipe across the top caps and clamp it with the included 3/8" U-bolts. Add a second row if your panels are tall or you're mounting in portrait.
6. Attach rails and panels
Bolt your panel rails to the cross pipe, then mount the panels to the rails using the panel maker's clamps. Space the rails to match your panels' mounting holes.
7. Wire it up
Run your wiring to the charge controller or inverter following the equipment instructions and local electrical code. If you're not comfortable with electrical work, have a licensed electrician do this part.
Want every detail?
Our Layman's Guide to Build an Off Grid Solar Array walks through the full build with locally sourced parts, available on Amazon.
Parts
Mounts used in this guide
Array top cap
2.5" Pipe Array Top Cap
- Fits 2.5" (2 7/8" OD) ground pipe
- Build arrays from 1 to dozens of panels
- Set bolts + two 3/8" U-bolts for the pipes included
Top of pole mount
2"–3" Pipe Top of Pole Mount
- Fits 2" (2 3/8" OD), 2.5" (2 7/8" OD) or 3" (3.5" OD) ground pipe
- Up to 3 large 300-400W panels or up to 6 100W panels
- Adjustable tilt, pipe U-bolts included
Top of pole mount
4" Pipe Top of Pole Mount
- Fits 4" (4.5" OD) ground pipe
- Up to 3 large 300-400W panels or up to 6 100W panels
- Adjustable tilt, pipe U-bolts included
FAQ
DIY solar array questions
Can I build a solar array without welding?
Yes. Bolt-on top caps and top of pole mounts clamp to standard pipe with bolts and U-bolts, so no welding is needed.
What pipe should I use for a solar ground mount?
Galvanized schedule 40 or 80 pipe, or oilfield pipe. Match the ground pipe to your mount size and use 2" (2 3/8" OD) pipe for the cross pipe.
How many poles do I need?
It depends on your panel count and size. One pole can hold up to 6 small or 3 large panels with a top of pole mount. Larger arrays use top caps on 2-20 poles.