How to Make Homemade Solar Panels

Complete Homemade Panel

We have already learned to wire solar cells in a series, the hard part is over. Now we can assemble our panel and produce electricity from the sun. This is a great way to turn a small amount of cash into big savings.

Things You'll Need

• Solar Series pre-wired
• plywood
• UV Guard
• Screws
• Plexiglas
• Caulk
• drill bit the size of your screws

Instructions

1. 

   We have already wired our solar cells (article in the resources section) now we are ready to turn them into a energy producing solar panel. This process involves building your box and drilling guide holes for wiring everything up correctly. Your box can be as simple or elaborate as you choose it just needs to get the job done. Your box should be sturdy, and water proof, with a way to keep your panels from getting damaged. This will be a rough guide as your dimensions will be determined by the size of your solar panels.

2. 

   The solar panel box above was built using one sheet of 3/4 inch plywood for the base. It was framed out using 3/4 inch pieces of wood around the edges. You can see that the box is sectioned off by another 3/4 inch piece of wood. This solar panel box is designed to hold 2 solar panels within it. Your wood should be heavily coated with 3 coats of UV Guard or some similar form of UV protection. Deck or fence sealers will work as well as paint however you will need to use many coats. The goal is to keep the damaging UV rays of the sun from damaging your wood.

3. 

   You can see in this picture that holes were drilled through the frame of the box to provide ventilation. As your solar panel is exposed to extreme temperatures this will keep your box from warping in the heat of the sun. This is an optional step that can save you money in the long run. Knowing the conditions in and around your home will help you decide what steps you need to take.

4. 

   A layer of Masonite peg-board is cut to fit loosely in the wells and after being coated with UV guard placed inside the solar panel box. This is what the solar cells will be attached to for easy maintenance if a problem should occur. In the place of peg-board you can use cardboard, or any other non conductive material. This is a great way to recycle things you don't need anymore, old paint, Sheetrock, even old floor board mats would be great for this use.

5. 

   When attaching the solar panel to the substrate you want to be careful not to damage it. Add a glob of caulk to the center of each cell,is more than enough to hold it in place. You do not want to apply so much caulk that you glue them down completely as this will keep them from moving with the wind and break your cells. Using caulk in the middle of your solar cells is the easiest way to combat this problem and prolong the life of your solar array. You can use all purpose silicone caulking even the cheapest will work.

6. 

   Lay your substrate material on to the solar cells positioning carefully and allowing the caulk to dry. Once everything is dry you can flip your assembly over and fit it inside your homemade panel box.

7. 

   Using 2 pieces of properly gauged copper wire attach your positive leads and negative leads in series. Your positive leads should all be soldered to one piece of copper wire and your negative leads should be soldered to another piece of copper wire. This gives you a positive and negative terminal that will be leaving your box. Drill holes for your copper wires to leave the box and later be wired into your inverter. In the resources section is a guide for choosing the right type of copper wire for your application. Solar panels are unique to the homeowner and your materials for building it will be unique also.

8. 

   If you are using 2 different panels inside one box they need to be wired in a series as well. Each panel in a solar array needs to have a blocking diode installed to prevent damage to your batteries and inverter. Install this diode per the manufactures instructions. This insures that your solar power equipment and home will be safe.

9. 

   Once you have everything wired up and working properly you can install your Plexiglas top. Drill pilot holes to keep your Plexiglass from breaking using an appropriate sized drill bit. Take caution as you do not want to apply too much pressure to your Plexiglas. Use a bead of caulk around the edge of your box, line up the Plexiglas and screw it down. You can add any edging that you wish remember the box can be as simple or elaborate as you wish.

10. 

    Be creative in your choice of panel materials. I have seen old windows and new windows be used in homemade solar panel construction. This is a great way to ensure your panels stay out of the elements, especially if you have south facing glass, or angled glass on your home.

Tips & Warnings

• It is not necessary to install your solar cells on a substrate however it makes for an easier maintenance.

• You can use window glass for a solar panel application but remember that hail can break it pretty easily.

• Coat with at least 3 coats of UV guard, you can then paint your solar panel any color you wish.

Resources

• Solar Array built by Michael Davis
• Homemade Solar Panel Design
• Using DIY Solar Cells
• Wire Solar Cells
• Wiring Chart