How to Build a Solar Collection Panel
Building a solar panel is not a difficult task and it can be done at home out of easily obtainable materials without any specialized knowledge. You will need basic knowledge of carpentry and simple electrical wiring. The solar panel consists of two basic parts: the solar array and the framing structure. First you will build and test the array as its own piece. Once the array is complete, you can build the frame structure, install the array and begin using the panel. Does this Spark an idea?
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Things You'll Need
- 36 mono-crystaline solar cells
- 45 3/4-inch by 22 1/4-inch piece of plywood
- 45 3/4-inch by 22 1/4-inch piece of Plexiglas
- 135 inches of 3/4-inch by 3/4-inch wood molding
- 18-inch by 36-inch piece of masonite pegboard
- blocking diode
- electrical jack
- solder
- copper wire
- silicone caulk
Instructions
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Constructing the Solar Array
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1
Place the solar cells face down on the plywood in six rows of six.
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2
Solder the cells together using copper wire. Be sure to use separate wires for the positive and negative leads. Also, be sure to touch on each soldering point or the solar array will not function. Leave about one foot of extra wire at the end of the array for connecting the blocking diode and electrical jack.
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3
Place a dab of silicone caulk in the center of each cell and then place the masonite pegboard over the cells so that it covers all of them. Allow the caulk to dry and then carefully flip the entire configuration over so that the solar array now rests on the masonite pegboard and the plywood can be removed for constructing the frame.
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4
Test the array with a voltmeter and ensure that it functions properly.
Constructing the Panel
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5
Frame the entire perimeter of the plywood using the 3/4-inch by 3/4-inch wood molding. Secure the frame with wood screws.
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6
Cut a 1/2-inch notch in the bottom of the frame to run the excess wire from the array through.
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7
Place the masonite pegboard with the solar array on it in the center of the frame and secure it to the plywood with screws. Be sure not to damage any of the wiring or cells.
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8
Run the excess wire from the array through the gap in the frame. Solder a blocking diode and an electrical jack (if your installation requires one) onto the end of the excess wire.
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9
Cover the solar panel with Plexiglas and secure the Plexiglas to the frame.
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1
Tips & Warnings
Mono-crystalline solar cells are very expensive. You can acquire them for a fraction of the cost by purchasing lots of slightly damaged cells from manufacturers or online auctions. Slightly damaged cells will produce fewer watts than pristine cells but it will not make a large difference once they have been incorporated into the array.
