These are strong and portable.
Step 1: Supplies
four 12"x36" pieces of wood
six small hinges
craft glue and gun
two long strips of strong fabric
40 laminating pouches (10 mil thick)
copper slug and snail tape
two alligator clamp
40 3x6 solar cells
clear Scotch tape
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
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
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
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
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.