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The frame pivots (5a, b, and c) are two short pieces of angle with some edges trimmed, bolt holes drilled, and welded into a "T". The diagrams for the pieces show how they should look when finished.

Assembly

For simplicity, we fitted and mounted the top pole pivot onto the pole before raising it. This allowed for an easy work space but the overhang of parts 4a and 4b must be oriented southward when the pole is permanently set—which was difficult to maintain while setting the pole.

With post hole diggers we dug a 6' hole and then, using a gin pole, we hoisted the massive locust post into the air and sank it into the hole. When setting your pole, use a 4' level to maintain plumb while filling in around the base with concrete. Then tamp rocks and dirt into the hole, keeping true while filling it the rest of the way.

Once the pole is up, erect scaffolding along side of it to provide a safe work space for the higher-altitude assembly.

The first piece to go up is the spine. It can be preassembled on the ground; set 2a and 2b back to back and bolt frame pivots 5a, 5b, and 5c in their positions on the flat side of the spine. Use lock washers on the bolts and tighten snugly. Notice that when the frame pivots are installed, spine pieces 2a and 2b, though oriented back to back, do not touch. This opening allows for the top pole pivot (piece 4) to fit between 2a and 2b with a single bolt passing through all four pieces (4a, 4b, 2a, and 2b), creating the main hinge that holds the entire array. Pull the assembled spine up the scaffolding, and bolt it in place to the top pole pivot, making sure that the bolt hole on the spine for the angle brace is facing the downward side.

Bolt the brace (piece 3) to its hole in the spine, and then lag bolt it back to the pole in a position that allows for easiest access for installation of the remaining pieces from your scaffolding. Notice the brace has multiple holes on the end towards the pole; this allows for the adjustment of the array for higher summer sun tracking or lower winter sun tracking.

Next carry up and bolt the frame pieces in place (1a, 1b, and 1c). Take care to mount 1b to the center frame pivot (5b); this frame piece has holes drilled at either end for attaching the turning cables. Snug these bolts down, but not so excruciatingly tight that they won't allow the frame to pivot. Adding a bit of grease between the frame and pivot will help the process as well.

Using 3/8" carriage bolts with lock washers, bolt the 1 x 4 oak purlins onto the frame. It may be easiest to C-clamp the boards to the frame pieces in place, and then drill by running the bit through the holes already in the angle pieces, and bolt them from the scaffolding. Note that you may wish to configure the purlins slightly differently than we have to accommodate other kinds of panels. The important things to keep in mind are that the array should be equally balanced in weight on either side, and that the weather tight electrical boxes on the back sides of the panels should be kept to the side of the purlins for accessibility. You also may want to treat the purlins with a wood preservative before sending them up.

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