Guide for Homemade Solar Panels

A solar panel is a collection of smaller solar cells.

Solar panels can cost as much as several thousand dollars on the open market. So, it may be desirable to produce a solar panel on your own. You will need to be fairly handy with wiring and electrical work, but it can be done. Using smaller solar cells, you can wire together a larger solar panel for a fraction of the price of a completed solar panel. In addition, the parts to build the solar panel can be bought used, also reducing the cost.

Things You'll Need

• Wood
• Wood glue
• Hammer
• Nails
• Peg board
• Paint
• Solar cells
• Tab ribbon
• Soldering iron
• Solder
• Silicone caulk
• Plexiglas sheet

Instructions

1. Plan the size of the solar panel you will be building. Ideally, you will size the system based on the amount of voltage you will be attempting to produce. To decide on the system size, determine how many solar cells you will need to produce the amperage and voltage desired from each solar panel, and plan to build the box for the solar panel large enough to hold that many solar cells.

2. Build a shallow box out of wood according to the dimensions you decided upon in the previous step. Paint the box. Install a backing in the boxes that will hold the solar cells, such as a peg board cut to fit the box.This should also be painted to ensure the frame has a longer life.

3. Place the solar cells next to each other in the box to ensure they fit.

4. Connect the solar panels using tab ribbon. In order to ensure the cells are appropriately connected, pre-crimp the ribbon by pressing down on it to create a small indent in the tab ribbon. The crimps should be spaced to fall between each solar cell.

5. Place the connected cells into your box to ensure they fit as a connected unit. If they fit, place a small dab of silicone caulk on the back of each cell and press them down to glue them into place on the backing.

6. Add a Plexiglas cover to the entire box to protect the solar cells.

Tips & Warnings

• Purchasing "pre-tabbed" solar cells can reduce the amount of soldering that must be done as these cells already have tab ribbon soldered on. However, they are also more expensive.

• When picking a paint, it is a good idea to consider a heat-resistant paint, as solar panels can become quite hot.

• Solar cells are very delicate. Take care when handling them, and consider putting down padding in your work area in case you happen to drop one.

References

• MD Pub: Solar Panel
• "Build Your Own Solar Panel"; Energy4Green; 2008