Travis,� I can help you out.� Every install is a bit unique, due to different surfaces, so it's hard for the installation manual to cover everything.
1) Depending on the siding, you may need to shim under the rails to make sure they are square to the SolarSheat.� The foam gasket that goes around the holes is pretty flexible, but if it is on a non-flat surface, you may need to use spray foam to get a good seal, or as you suggested, cut more of the siding around the gasket to be up against a flat surface.� Again, use spray foam as needed to make sure there are no leaks.
You can remove all of the siding under the SolarSheats and frame it in, here's a great picture of a sweet install of a SH1000 on its side, framed into the siding,
http://yoursolarhome.com/solarsheat.com/solarsheat/pdf_solarsheat/SolarSheat1000G_Specs.pdf 2) Hard to say what size hardware based on what material it is screwing into.� For my house, screwing into 2x4s, I used lag bolts, probably about 2" long, 1/4" diameter (sorry, it was a couple of years ago, I don't remember exactly).
3) Because they have no idea where the studs will be to drill into, they can't pre-drill the holes in the mounting bracket.� You'll need to drill the holes where they line up for you.� Generally 4 holes, evenly spaced.
4) You can install it on its side (I did).� You should use silicon caulking to seal around the knock out holes on the side to prevent water from seeping in.� Even though they are not knocked out, since it is pre-cut, water could seep if not sealed.� Rule of thumb to avoid shading, install 1 1/2 times below the overhang.� So if the overhang comes out 1 foot, install it 1 1/2 feet below that.
5) Yes, the SH1000 has the knockout to connect to another one with a gasket set.� We do have an AC version of the SH1000G, which doesn't have the PV panel, it is powered by plugging in the fan.� You can get that one as your second and just use the PV fan on the first one (so you are not paying for the 2nd PV panel).� They don't have plans to make a SH1000 without a fan, last I checked.
Give me a call if you have any other questions.
Amy Beaudet
Solar Thermal Queen
AltE Store