The effect of external-recycle operations on the thermal performance of double-pass cross-corrugated solar air heaters (SAH) under different operating conditions was investigated experimentally and theoretically. Additionally, the simultaneous ordinary equations were solved analytically for each proposed configuration. Four recycling types are introduced for improving the solar thermal performance with different external recycle processes, which are expected to enhance the heat transfer coefficient with a convective turbulent flow between the air and the absorber in the present study. Using recycling double-pass operations, two processes were conducted sequentially: air first flowed over the sinusoidal corrugated absorber plate and then flowed back later over the transverse sinusoidal corrugated bottom plate. Improved device performance was achieved due to the doubled heat transfer area over and under the corrugated absorber plate, from which both the sinusoidal cross-corrugated absorber plate and bottom plate enhanced turbulent intensity. Theoretical predictions and experimental results both indicated that the recycle ratio increased with the SAH thermal efficiency for all proposed designs. The results show a higher heat transfer efficiency for the proposed four configurations using wavelike corrugated plates compared to those conducted in single-pass and flat-plate absorber plates with up to a maximum 133% (from 0.301 to 0.703) increment. The optimal device performance was examined for all external-recycle configurations under the same working dimensions and operational conditions. The best configuration for optimal thermal performance was the device that lengthened the air flow pathway and increased the air velocity within the collector; thus, a higher heat transfer rate was accomplished. The evaluation of increments in the power consumption and of the heat-transfer efficiency enhancement together determined the optimal design based on an economic consideration across various configurations of cross-corrugated double-pass devices.