@madmike
just make sure you check with merchant, I think that "double wall polycarbonate sheet" has something like 60-70% light transparency, unlike normal polycarbonate sheet, which has close to 100%. This efficiency loss is significant. Try to cut this cost by build casing according to polycarbonate sheet measures. You can easily find cheaper sheets sold in one piece, rather then custom cut just for you from larger pieces.
I will build my next can solar heater just 10% smaller, but cover will be just 50% from original price...
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