How to Make a Portable Solar Powered USB Charger

MP3 players, cell phones and PDAs are just a few of the portable devices that charge with a USB cable. These items also happen to be portable, which makes them susceptible to a dead battery when you're out. Dropping into the nearest home or store to charge up isn't really an option but you can have power wherever the sun shines with this easy to build solar USB charger.

Instructions

Difficulty: Moderate

Things You’ll Need:

• Solar garden lights
• Drill
• Small gauge wire
• Candy Tin
• 1/4-inch mono audio connector
• Soldering iron and solder

1. Take apart the solar panel from a garden light assembly and remove the solar panel, battery and circuit board. Remove the wires and any old solder from the connections and mark the connection pattern for putting it back together.
2. Install a ¼-inch mono audio connector into the short side of the candy tin taking care to leave enough metal for it to hold onto firmly.
3. Thread the wires through the back of the tin along the hinge. Insulate the solar panel from touching the metal lid and secure it in place with glue.
4. Solder the ¼-inch mono jack to the contacts of the LED light. This gives you a way to verify that the unit is working and the power is flowing.
5. Insulate the inside of the candy tin and solder the remaining contacts. Place the circuit board and wires into the box being careful not to place stress on the connections. Cover any bare connections with tape or silicon so there are no shorts.
6. Connect your USB device through the ¼-inch mono jack and confirm it is charging. Look for a short circuit if you're not getting a charge and insulate that area.

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