The price of solar panels has prompted many pioneering individuals to perform do-it-yourself installations. If you are planning to build your own solar panels, you should follow some specific steps.
To build the box for your panels, you’ll need some 1/2″ plywood, 1/4″ pegboard, and 3/4″ x 3/4″ strips. The plywood should be two feet by four feet. Cut the strips to attach around the outside of the plywood making a band. Put one more strip in the middle, and cut the pegboard to fit within the two banded areas. The pegboard should not fit snug.
You will need a 1/4″ thick piece of Plexiglas cut the size of the overall panel for a cover. Drill holes about every 6″ around the edges and across the middle to allow for attachment to the 3/4″ wood strips.
Generously paint all sides of the pegboard and the wood with exterior grade paint. Silicone caulk will be needed to fill all cracks and create an airtight seal. When you are finished with the assembly, use clear caulk to seal the Plexiglas to the box front. Further sealing is accomplished by using silicone in screw holes and on the tops of the screws after installation.
You will need about 40 solar cells for your panel. The mono-crystalline cells are sold in bricks consisting of about 18 cells each. The cells are brittle and easily broken, so consider purchasing extras. Buy the cells that have tabs on them. This will save you time when soldering them together.
Arrange the cells in a design that will work within the usable areas of your panel box. When you know where the cells will be placed, solder groups of cells in easy to manage cell sections. Attach these to the pegboard with a small amount of silicone. Do not apply too much adhesive because the cells must be able to expand, contract, and move independently.
After the last cell group is attached, wire each cell to the next in a series circuit. Two long wires will leave from the last cell and drop out a hole at the base on your solar panel. This is your power source.
Seal the Plexiglas cover to the front with silicone and screws, sealing the screws afterwards with silicone. Use screws that are smaller in diameter than the holes, being careful not to overtighten them as this can crack the Plexiglas.
Examine your panel one last time to be sure it is water tight, and you are ready to make electricity. In full sun, check out your top voltage with a meter. Your rate should be close to the rated output total of your cells. You now have the basic information needed to build your own solar panels.