Hi Everyone, Today I'm going to show how I built this solar
food dehydrator. First we'll start with making the base. The
entire frame is made with 2 by 3 by 12 foot pieces which minimizes the scrap. The final
base size is 36" wide by 48" deep. Depending on the width of the glazing, you may want
to make yours slightly more narrow because the finished plywood will make the body about
36.5" wide. I decided to use construction adhesive at all the seams along the exterior
to help to minimize air from leaking at the joints. I'm not sure if it really matters,
but it's just for peace of mind. The shell is made from 3/16" plywood, but there's no
problem using 1/4" if you can't find 3/16". The rear wall acts as the chimney to help
with the air draft through the dehydrator. At the top, I cut each of the 2-bys at a 45
degree angle so I can put a small roof over the vent to minimize rain from getting in
the dehydrator. The plywood hangs over the end of the 2-bys by 2.5 inches so that it
can be used to anchor the rear wall to the base section. The top of the sheet ends around
8 inches from to top. This is where the air will exit. On the front of the chimney, I cut the plywood
at an angle so that it would match the angle of the roof section. At the base of the chimney,
I left it a couple of inches from the bottom to allow the air to flow a bit easier into
the chimney. This entire section is also glued and nailed together. Next is to attach the back chimney wall to
the base. Just plywood holds the two sections together with a little glue and nails. It
may not look pretty yet, but I usually prefer function over aesthetics. I then square the
two sections and add a temporary cleat to maintain their positions. The solar collector is next. On mine, I made
it 73.5" long and it draws the cool air in from the back. However, most sheets of acrylic
are around 70" long so you may want to make this a bit shorter and draw the air in from
the bottom. The top section is cut at a 45 degree angle so that it will match against
the back chimney. Instead of using a full sheet of plywood, I used to remaining sections
of scraps. Since this joint is between the solar collector and the drying racks, it really
didn't matter if some air sneaks between this joint. There should be around 6" of space
at the top end of the plywood so the hot air can get into the dehydrating area. Before attaching the solar collector section,
I added some rails along the rear chimney wall. These are just made from some scraps
that I ripped down to be around ¾" square. They are spaced so the racks will be2" apart
on center. I then made up some more rails that are attached to a 2 by 6 that I ripped
a 45 degree angle along its edge. This will attach into the solar collector. With the unit lying on its back, I attached
the solar collector between the base and the chimney wall with some nails or decking screws.
This triangle shape makes the unit very rigid and then the cleat can be removed. To set the rails under the collector, I cheated
just a little so I could make sure the drying racks would be level with the racks attached
to the chimney wall. I took two pieces of scrap and measured the height of each rail
and cut the scraps to that height. I then temporarily attached the scraps to the new
rails so they acted as legs to hold them at the proper elevation. Then added some glue
and screwed it into place through the collector's plywood. For one side of the collector I fastened on
a piece of plywood. It doesn't need any structural support so there are no studs built into it.
At this point, I ran out of glue and I didn't feel like going to the hardware store so I
just attached it with nails. When it's complete, the dehydrator will weight
a few hundred pounds and I wanted to be able to move it around and align it with the sun,
so I made up an axle out of some scrap black pipe and found some old riding mower wheels.
There's always a good reason to save old junk like these wheels! For the door, I made up a few brackets and
anchored them into the base. They are tapered so when the door is resting on them, they
will force to door tight against the frame. Then around the rest of the perimeter, I made
up some little turn-knobs that hold the door in place. It only takes a few seconds to open
and close the door. It's not a perfect seal so at some point I may add a foam gasket in
around the door frame. One last piece is to add a little roof over
the chimney so that it helps to keep some of the rain out of the dehydrator. The entire thing is painted with flat black
exterior latex paint. It took about two quarts to put on two coats. Even the sides should
be painted so if the sun hits it, it will help to keep it warm. This next part is optional depending on your
location. Here in the northeast, we need to try to maximize our solar collection as much
as possible. In sunnier areas, you should test your dehydrator to make sure it doesn't
get too hot whereas you start to cook your food instead of dehydrating it. Take some expanded steel plaster lathe and
spray paint both sides of it with flat black paint. It's best to just paint a few sheets
together to minimize your paint loss as it blows through the lathe. You can try to be
complete, but don't worry about getting 100% coverage. Then cut the sheets into pieces
so that the width will fit into the cavity of the solar collector. To mark the cutting
line, I just ran a piece of tape along the cut line since it was difficult to see a chalk
line. Inside of each cavity install a cleat that runs from about 3/4" from the top of
the cavity down to the bottom. I stacked 5 layers into each section to absorb as much
light as possible. I couple of sheetrock screws hold them in place and I then touch them up
one more time with some spray paint. As the air passes up through the collector, it is
forced through each of these "solar sponges" and the heat that is absorbed into the metal
is transferred into the air. You can see as I stack each layer in the sun,
less light is able to get through to the bottom. Even though these are flat black, some light
does bounce off of the surface, but a percentage will hit the backside of the layer above it,
helping to maximize the light absorption. I also added one more wheel to the dehydrator.
After attaching a cleat and painting it, I attached a swivel castor to it. It makes it
far easier to push it around now! Along the bottom opening, it's a good idea
to add some screening to keep the bugs from getting up inside the solar collector....unless
you like dehydrated grasshopper! To attach the sheet of acrylic, I drilled
a bunch of holes through it and fastened it to the frame with some screws and washers.
You want to make sure the holes are extra-large because the acrylic will expand and contract
with the temperature changes. The best trick for drilling holes in acrylic is to run the
drill backwards so that it will melt its way through the plastic. When screwing the acrylic
down, don't over tighten it so it can still move around a bit. I had to add one little
extra piece along the bottom because I purchased the acrylic after I build the solar collector
and had the wrong measurements....so you can learn from my mistakes! The last part of the project is to make some
drying racks. I used some scrap lumber and ripped it down to be about 3/4" square. Then
I took some scrap plywood and made some corner brackets and glued and tacked them to each
corner. Next I stretch some fiberglass screen over each rack and stapled it into place.
After I ran out of the fiberglass screen, I found some pet screening. It's a bit thicker
and smoother and I'm finding that the food doesn't stick to it much. I wanted to get
some stainless steel screen, but it was far outside of the budget. After waiting for a few days for the paint
to fully cure, it's finally time to give it a test drive and move it to its new home near
the greenhouse. We happen to have some fresh peaches on our tree and sliced them up to
about 1/4" slices. After a couple of days of drying at around 145 degrees, it was time
for a taste test. Not many of the slices made it back to the house so I loaded it with a
bigger batch. Thanks for watching, please don't forget to
like this video, subscribe to our channel, and leave comments about your solar food dehydrator.
