Redneck in training
Elite Member
Before using some alternate to the standard rails and clamps for panel mounting, it would pay to find some install manuals on-line and read the mounting recommendations, warranty invalidation for non-approved mounting methods and so forth.
I noticed the installers used a torque wrench on every bolt in my system. I am assuming it matters.
Attaching the panels to a wood frame without the mounting rails might be a risk. The wood can warp, cup, twist, shrink, expand, etc. The aluminum frames on the panels aren't going to like any of that. There is also the chemical reaction possible with treated wood in contact with metals to think about.
Some things to consider before you decide the cost of rails and clamps isn't worth it. Just for the ease of installation, I would think those are worth quite a bit.
If you do build your own mounting frame, I would consider designing it to easily allow adjusting for three fixed panel angles -- winter/summer/fall+spring. I assume in Iowa snow depth accumulation is not much of a problem, ground mounts would be my choice for ease of install, maintenance, etc. on a large system.
I already decided to use solar mounting rails and associated hardware. I also figured that at current cost of the panels it is easier just to make the system bigger than to go to the complication with tilt adjustment.