Custom Solar Bimini for Hallberg Rassy 46

Ocean Covers recently completed a custom stainless steel Bimini structure for a Hallberg Rassy 46, integrating six flexible Solbian solar panels (for a total of 744W) for sustainable energy generation during long offshore passages.

Project Objectives

• • Design and build a marine-grade Bimini structure to support 744W of solar power
  • Protect the centre cockpit from sun and all weather conditions
  • Ensure full accessibility to winches and cockpit functionality
  • Hide and protect all solar cabling
  • Deliver a solution strong enough for offshore conditions

Key Challenges

• • • • Boom clearance: The structure needed to fit under the boom while allowing enough angle for rain runoff.
      • Offshore strength: This vessel will be sailing in offshore conditions, so the structure had to be exceptionally strong and reliable.
      • Tight timeframe: The project had to be delivered on schedule before departure.

Our Solutions

Ocean Covers handled the full design, manufacture, project management and installation of the Bimini frame and canvas.

• • Structure: Fabricated from 32mm 316 marine-grade stainless steel tubing, with eight fixing points. Every point was through-bolted with internal stainless backing plates to distribute loads and ensure long-term durability.
  • Solar Support: The structure was designed to mount six Solbian flexible panels, securely fixed and aligned for optimal performance.
  • Canvas: Sunbrella marine canvas was used, with zip-on pockets for the solar panels and attachment to the frames. All seams were sewn with Tenara thread for UV resistance
  • Accessibility: The frame structure was carefully measured to maintain winch handles clearance and entry/exit to the cockpit.
  • Custom Add-ons: As requested by the owner, stainless steel ladders and handles were added to both sides of the structure.

Results

The final result is a sleek and highly functional Bimini that delivers both energy independence and cockpit protection — without compromise on accessibility or durability.

The canvas can be removed easily and stored for long period of absence from the boat or extreme weather conditions.