Build your own Solar Panel

It's fun and rewarding to know how to build your own solar panel from scratch. As usual with any project the better organized you are and the more planning you do in advance the better the results you'll get. You'll need to have somebasic soldering skills as well. Don't panic though - a 15 minute soldering lesson from a trusting friend or neighbor will see you up and running and give you all the soldering knowledge you need to successfully build your own solar panel.

The first thing that you'll need to source in order to start making your panel are some basic materials, namely a stack of solar cells, more technically known as "photovoltaic cells" or just PV cells. They can be bought new or acquired second-hand from various places depending on your budget.

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New cells can be found at great prices especially if your shop around. But if buying second-hand make sure you get some kind of warranty that they're in reliable working order.

Cells have specific Watt ratings; the number of cells you'll need to buy will depend on how much electricity you want to generate. The important thing to remember is to assess your energy use first before commencing to build your own solar panel.

You'll also need to make suitable trays (or boxes) into which to mount your panels. Masonite is a popular material for backing tray's whilst cedar or hardwood are good, durable options for making the frame. You can also choose to fabricate your trays from aluminum if you wish depending on your time and budget. Always take care when mitering the corners to make sure there are minimal gaps. Also minimise sharp edges to avoid cutting yourself during handling and installation.

If you make your trays early on in the process it can assist with final placement of the cells; it will make soldering easier if you first lay the individual cells into position on the tray. Alternatively you can lift (or slide) the completed panel into it's tray

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later on (after all the cells are joined) but this can be difficult without damaging any of the linked cells. You should also drill several holes for the wiring to protrude from on the edge of each tray and another for ventilation in order allow condensation to escape.

Wooden trays should be sealed with a couple of coats of waterproof, and if possible, UV resistant marine varnish. You'll also need to make suitable tray covers out of glass or plastic. Obviously plastic is the most workable material - and probably the most durable.

Make sure that all of your cells are dry and clean. Arrange them inside your frame (or on some other flat surface) being sure to handle them very carefully so that you can join them neatly and prevent damage.

Once the cells are in place you can commence joining them. Applying flux will help the solder to adhere (buy yourself a flux pen - they're only a few dollars and are ideal for this kind of work). Also remember to be very clean with your soldering. Solder the cells together in series using copper wire along their conductive pathways.

Some people prefer placing a dab of silicon on the back of each cell before fixing it to the inside of the tray. Feed wiring out through the side and run a bead of silicone adhesive around the tray frame. Then, place your cover on top and screw it down adding more silicone over the screw holes and wiring points.

Now repeat the process until you've finished building all of your required panels. The solar panels should then be joined together to create, thus creating a photovoltaic array. As your already waterproofed them you can then start to think about installing and mounting your new solar array.

I strongly recommend that you check some of the more popular and inexpensive guides available which take you through the entire process, allowing you to successfully build your own solar panel - with complete confidence - from start to finish.

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