Instructables
Picture of 80 Watt Quad-Fold Solar Panels
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These are strong and portable.

Step 1: Supplies

You'll need:
four 12"x36" pieces of wood
six small hinges
electrical wire
craft glue and gun
velcro
two long strips of strong fabric
40 laminating pouches (10 mil thick)
copper slug and snail tape
two alligator clamp
wood sealant
40 3x6 solar cells
clear Scotch tape

Step 2:

Step 3: Prepare The Wood

Sand, stain or paint to your liking. let dry while we move on to the next stage.

Step 4: Cell Prep

Picture of Cell Prep
Solder tabbing wire to your 40 solar cells using four pieces of tabbing wire 4 inches long for each cell.

Step 5: Fold Tabbing Back

Picture of Fold Tabbing Back
After all the cells are laminated fold back the positive tabs on half the cells to the back side of each laminated cell as shown. Maybe kinda hard to see.

Step 6: Laminate

Picture of Laminate
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Laminate each completed solar cell by centering the cell in the laminate on a towel on a hard surface... towel not shown in this picture. Be sure to use the laminate sleeve or make one with thin card board. Use your hot iron to press lightly as it shouldn't break the cell and hold the heat to all four edges for five seconds each. quickly remove the hot laminated cell and pinch your fingers along all the edges with a little force just like you're trying to seal a zip lock bag. This will take the place of a laminating machine and really seal all the edges good. You may need to reheat you laminated cell a second time in order to finish pinching the edges together as it cools pretty fast. The only place moisture can get in is where the tabbing wire pokes out from the laminate. You can use silicone caulk to further seal these areas.

Step 7: Pay Close Attention

Picture of Pay Close Attention
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Now you're going flip them all over face down and solder two laminated cells together at a time. Solder the two negative tabs to the two folded back positive tabs. Butt the laminated cells up close together before soldering, this was the reason for folding back the tabs. It's okay to burn a little laminate in this process. Pictures show two soldered cells together.
 
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Macattacku12 months ago
1. Why did u say it three times? And 2. What you are measuring is open circuit values. In circuit values such as while charging a battery or running a load will be 18-20 volts at just over 3 amps.
Solaron (author)  Macattacku12 months ago
But my instructable never mentioned open circuit or operating values it just said 80 watts which is correct, and to answer your first reply. Its not 1.6 watts per cell. So what point are you trying to argue?
Macattacku Solaron12 months ago
Ok did you put the meter right on the panel when you weree measuring these values?
Solaron (author)  Macattacku12 months ago
Yes i did. Which is open circuit values, i get it. It will drop once it's put to a load, totally understnad that. It's fair to say that it starts at 80 watts. These values used in the 80 watt determination were strait from the values advertised on the website and the actual opebn circuit readings i got when i measured the current. Again, my post did not specify open circuit or operating values it simply stated 80 watts based on my meter readings.
Macattacku Solaron12 months ago
Ok then that was my point. Open circuit values arent acurate. Taking an amperage reading off tge panel for 3.7 amps is a shorted amerage reading and will have almost no voltage therefore only about 0.5 watts or so is being produced. Same with voltage. You are measuring voltage with almost no amperage, only the couple of tenths of milliamps the meter uses.
Solaron (author)  Macattacku12 months ago
If the cells were 1.6 watts like you originally stated, then 40 x (3x6) cells = 64 watts is not accuarte then either since that would be an open circuit value as well.
Macattacku Solaron12 months ago
K. Sorry to drag it on. But 64 watts would be manufacturor specs. 1.6 watts ~0.5 volts is manufacturor maximum load rating. It is rated at 1.6 watts is the maximum power it can deliver under load.
Solaron (author)  Macattacku12 months ago
The website also says that the 1.8 ways per cell is an average power out put.
Solaron (author)  Macattacku12 months ago
Your're not teaching me anything here. So it's 80 watts open circuit voltage and short circuit amps. Like i said i get it! I'm not changing the title and your not going to get anywhere with me.
Macattacku12 months ago
Thats only a 64 watt panel. 3x6 cells are 1.6 watts. 1.6 x 40 = 64 not 80. And you should just hook up a panel to a battery. You should have a charge controller so you dont over charge and damage the battery.
Solaron (author)  Macattacku12 months ago
No Macattacku, you are wrong, but thanks for your concern. First of all, where i get these cells they are rated at "at least" 1.6 watts if they are broken or missing any portions which mine don't and if they are missing anything, it's so small it doesn't really matter. They usually send me plenty of perfectly good ones in my order which i tend to use. Second, i have a multi-meter that tells me this particular panel put out 22v at 3.7 amps. You do the math genius :) That's 81.4 watts not 64. Anything else you'd like to add? Oh ya, good information on the battery too. If you wanna do an istructable on connecting to a battery go ahead. I was giving out general information.
Solaron (author)  Macattacku12 months ago
No Macattacku, you are wrong, but thanks for your concern. First of all, where i get these cells they are rated at "at least" 1.6 watts if they are broken or missing any portions which mine don't and if they are missing anything, it's so small it doesn't really matter. They usually send me plenty of perfectly good ones in my order which i tend to use. Second, i have a multi-meter that tells me this particular panel put out 22v at 3.7 amps. You do the math genius :) That's 81.4 watts not 64. Anything else you'd like to add? Oh ya, good information on the battery too. If you wanna do an istructable on connecting to a battery go ahead. I was giving out general information.
Solaron (author)  Macattacku12 months ago
No Macattacku, you are wrong, but thanks for your concern. First of all, where i get these cells they are rated at "at least" 1.6 watts if they are broken or missing any portions which mine don't and if they are missing anything, it's so small it doesn't really matter. They usually send me plenty of perfectly good ones in my order which i tend to use. Second, i have a multi-meter that tells me this particular panel put out 22v at 3.7 amps. You do the math genius :) That's 81.4 watts not 64. Anything else you'd like to add? Oh ya, good information on the battery too. If you wanna do an istructable on connecting to a battery go ahead. I was giving out general information.
I think this is a pretty good home-based unit. I wish it went a little further though, as to how to hook it to a battery, or some such. I need to do more studying though.
Solaron (author)  Terri Hunter1 year ago
Thanks Terri, glad to hear you like it.
I'll give you the basics:
Just clamp the alligator clips to a 12 volt car or 12v deep cycle battery. Black goes to the negative and red to positive on the battery.

I recommend the deep cycle battery as regular car batteries aren't designed to be drained and recharged. Deep cycle batteries are.they both look the same though and deep cycle batteries are commonly used in cars too.

You could also clamp them directly to a12v power inverter. same thing with the colors. This will convert the electricity to ac instead of dc current. This makes it possible to run our charge things that use a regular plug in the wall plugs.

Just be careful because you are dealing with electricity. Hope this helps.