Build a Solar Panel

Solar cells

Depending on what size solar panel you are going to build, will dictate how many solar cells you are going to need. The cheapest way to get solar cells is either from eBay or find a local firm who uses solar cells in their equipment. Road signs often use solar powered cells and are frequently getting damaged and are chucked away. These companies don't repair the actual cells, they just replace them. So you can salvage them and use them in your panel.

Strong Plywood

The frame of your solar panel is made from this sheet of plywood. Get a good sheet of flat plywood and cut it to size. The plywood will be painted with a UV protector ensuring the elements do not destroy your panel for many years.

Soft or Preferably Hard Wood

If you can afford hardwood then get this as it will last longer when left outside at the mercy of the elements and again we will treat it with a UV protector to enhance the lifecycle of your solar panel.

Flexi-Glass

Flexi- glass is used to protect the solar cells and all the electrical wiring. Some people like to use special glass that has the ability to collect infrared light. This is expensive but it will make your solar panel more efficient as the infrared feature will allow you to convert the suns energy in cloudy conditions.

Soldering Wire - Tabbing Wire

Tabbing wire is great for connecting the different solar cells together and so making a complete solar panel assembly. The tabbing or soldering wire is manufactured from tin and has a very melting point.

Silicone Gun

Silicon is used to make the solar panel water tight by filling the gap between the flexi glass and the wooden frame. The second advantage is that it has some glue like properties and so can be used to secure the solar cells to the plywood.

Wiring Solder

The solar cells are joined to the copper wire using solder. The solar cells produce the current, and this current is then carried from the solar panel to your home and connecting to the inverter or batteries depending on which system you have employed. Sometimes the tabbing wire lifts of the backing board or cell, you can use the solder to stick it back down again.

Flux Pen

You use flux in conjunction with the tabbing wire, it ensures the tabbing wire sticks to the cells. The flux is essential for the tabbing wire to stick to the boards. If you do not use flux then the tabbing wire will not stick to the solar cells and no current will be able to run along it.

UV Protector

Paint the UV protector on to the plywood and the wooden frame to increase the life of the solar panel while it is left out in the sun.

Volt Meter

To check the output of each solar cell you connect the volt meter to it and then position the solar cell directly in the sun. The output increases as you add more solar cells.

If you require a more detailed explanation on how to build a solar panel, visit How to Build a Solar Panel on a Tight Budget.