Going off-grid has always been a goal of mine — but like most people, I didn’t want to spend $15,000+ on a system I knew I could build myself. After plenty of research, planning, and some hands-on work, I finally built a complete 48V off-grid solar setup for just under $5,000 — including solar panels, inverter, batteries, and mounting hardware.
Here’s exactly how I did it — with the full parts list, wiring overview, and some lessons I learned along the way.
🔧 My DIY Solar Setup at a Glance
- System Size: 3kW solar array
- Inverter: EG4 3000W 48V Inverter
- Battery: 5.12kWh EG4 Server Rack LiFePO₄ Battery
- Mount: Custom ground-mounted steel rack
- Use Case: Backup power + shed/workshop power + small appliances
⚙️ Why I Chose a 48V System
I went with a 48V system because:
- It’s more efficient than 12V or 24V setups
- It reduces wire size (saves money on copper)
- It pairs better with modern lithium batteries and inverters
The system is modular, scalable, and gives me the flexibility to expand later.
🧰 Full Parts List and Costs
| Item | Brand/Model | Qty | Price |
|---|---|---|---|
| Solar Panels (3kW total) | 6× 500W Tier-1 Mono | 6 | ~$750 |
| Inverter | EG4 3000W 48V | 1 | $599 |
| Battery | EG4 Server Rack 5.12kWh | 1 | $1,499 |
| Mounting Hardware | Custom Ground Rack (DIY steel + anchors) | 1 | ~$400 |
| Combiner Box + Breakers | Miscellaneous | 1 | ~$200 |
| Wiring + Lugs + Conduit | 10 AWG PV wire, 2 AWG battery cable, MC4s | – | ~$350 |
| Misc Tools & Supplies | Drill bits, lugs, fuses, etc. | – | ~$200 |
✅ Total: ~$4,998
🏗️ Building the Ground Mount
Instead of a pricey tilt rack system, I built a simple A-frame rack using galvanized steel angle iron and concrete deck blocks. This saved a lot compared to prefab ground kits and allowed me to customize tilt angle for my latitude.
- Tilt: ~30° for year-round production
- Spacing: ~1 inch between panels to avoid shading
- Anchoring: Concrete blocks + earth screws
⚡ Wiring the System (Simplified Overview)
Here’s a simplified layout of how I connected everything:
- Solar panels wired in 2S3P (2 in series, 3 parallel strings) → combiner box
- Combiner box → MPPT input on EG4 3000W inverter
- Inverter → Battery bank with 2 AWG cables, fused and isolated
- Inverter AC output → subpanel with breakers for loads
I used MC4 connectors, heavy-duty 2 AWG battery cables, and made sure to fuse everything properly on both DC and AC sides.
🔋 Battery Storage & Runtime
With the EG4 5.12kWh battery:
- I get ~3.5–4.2kWh usable (at 80–90% DOD)
- This comfortably runs:
- My fridge
- A few lights
- A fan or small power tools
- WiFi and chargers
In full sun, the 3kW array recharges the battery by early afternoon.
🧠 Lessons Learned
- Buy solar panels locally: I saved over $300 by picking them up at a nearby solar warehouse.
- Label everything: During troubleshooting, labeled wires saved me hours.
- Use oversized wire: I went up a size on most runs to reduce voltage drop.
- Start small and scale: This setup works great now — but I’ve left room for another battery and more panels later.
💸 Final Thoughts: Was It Worth It?
Absolutely. For under $5,000, I now have a reliable, scalable off-grid solar system that powers a small building, charges tools, and provides backup during outages. Plus, I learned a ton by doing it myself — and I’m already planning my next expansion.
If you’re looking to start your own off-grid solar journey, you don’t need a huge budget — just good components, a bit of planning, and a willingness to get your hands dirty.
🛒 Recommended Components (Affiliate Links)
- 🔋 EG4 3000W Inverter – Signature Solar
- 🔋 EG4 5.12kWh Battery – Signature Solar
- ☀️ 500W Tier-1 Solar Panels – Signature Solar or local pickup
- ⚡ 10 AWG PV Wire – Amazon
- 🧰 MC4 Connectors & Tools – Amazon
Purchases through these links help support this site at no extra cost to you — thanks!
