How to Make a Mini Solar Panel

A solar panel can be as large or as small as the number of solar cells you choose to use. A typical mono-crystalline solar cell is 3 inches by 6 inches and a typical solar panel consists of 36 solar cells. You can make a mini solar panel by using half the number of cells and cutting the size of the frame down to half as well. Of course, the mini solar panel will only produce half the number of watts as the full-size panel.

Things You'll Need

• 18 mono-crystalline solar cells
• 20- by 20-inch plywood
• 20- by 20-inch Plexiglas
• 3/4- by 3/4-inch wood molding, 69 inches long
• 18- by 18-inch masonite pegboard
• Blocking diode
• Solder
• Copper wire
• Silicone caulk
• Heat-resistant adhesive
• Box of 3/4-inch wood screws

Instructions

Constructing the Array

1. Place the solar cells face down in three rows of six on the plywood so that the solder points are exposed.

2. Solder all of the cells together using two copper wires, one for the positive lead and one for the negative lead. Be sure that you touch on each soldering point. If you miss a soldering point, the array will not function. Also be sure to leave about 6 inches of slack for connecting the blocking diode at the end of the array.

3. Place a small amount of heat-resistant adhesive on the back of each solar cell. Lay the masonite pegboard over the cells so that it completely covers them. Flip the entire configuration over so that the solar cell array is now resting on the masonite pegboard and the plywood is free to work with.

4. Place the solar cell array in direct sunlight and connect the positive and negative leads to a voltmeter to test the array. The voltmeter should measure about 9 volts if the array is functioning properly.

Building the Enclosure

1. Build a frame around the perimeter of the plywood using the 3/4- by 3/4-inch wood molding. Secure the frame with wood screws.

2. Place the masonite pegboard now supporting the solar array in the middle of the frame and secure it with wood screws. Be careful not to damage any of the cells or wires when screwing the pegboard down.

3. Connect the excess wire at the end of the array to a blocking diode. Be sure to match up the negative and positive leads to the negative and positive connection points on the diode.

4. Cover the array with Plexiglas. Drill lead holes through the Plexiglass at the corners of the frame with a titanium drill bit and secure the Plexiglas into place with wood screws.

References

• Mike's World: How I built an electricity-producing solar panel
• Home Solar and Wind: DIY Solar Panel
• Olino Renewable Energy: Building my own Solar Panel

Resources

• Solar Panels DIY