The picture above is of the completed panel. This panel was put up July of 2013, if produces an average peak of 40 watts. It is set at an angle of approximately 35 degrees and facing south.
Now for the materials:
- Wood for the frame
- Wood screws for the frame
- Wood glue for the frame
- Finishing coating for the frame
- Tempered glass
- EVA film
- Heat gun
- Sheet of FRP
- Soldered solar cells
- Brad nailer and nails
- Table saw
- Miter saw
- Other tools and materials.
This is what I used to put this together; you may come up with different materials and methods.
Disclaimer. When working on this project use your head, don’t do anything to hurt yourself. I used nail guns, heat guns, power saws, soldering irons, and other tools that can hurt you. If you don’t know how to use any of the tools I talk about then get someone to help you that does.
Now on to the fun!
To build the frame I used one 2x4 10 foot long. I ripped the 2x4 down the center so that I had two 10 foot pieces of almost square material on my table saw. Then I cut a rectangle piece out of that, and kept it for later.
Then cut the 4 pieces to fit the glass that you are using, remember the ledge that you made from your cuts will go to the inside to support the glass.
Also cut a piece of FRP the same size as your glass. This will cover the back of your panel.