It will include some of the things I got right and the things I got wrong while building my "Sun Suckers".
Please keep in mind that I am not qualified in this area and that my methods were based on a "research then trial and error" system.
Please use the ideas presented as a guide and improve on them wherever you can.
I won't be covering "in detail" panel building as such but will include helpful stuff (mostly discovered by the afore mentioned "trial and error' ) that wasn't covered in the many panel building Instructables and articles I read while doing my research.
Step 1: Learning. Think beyond today.
There's a lot of good info out there but there's a lot of rubbish too.
As a rule of thumb the greater the number of people say something, the more likely it is to be correct. Usually. But not always.
There are already some "Instructables" on panel building on this and other sites that contain credible and very useful information.
Very few of the articles etc. that I read, however, pointed out the life expectancy of the Solar Cells you'll be using versus the materials used in constructing the DIY panels.
The first Solar cells ever made still produce electricity and look likely to continue doing so for many years to come!
A piece of painted plywood used to mount your Cells on, on the other hand, will have a very limited lifespan under the hot conditions inside a panel.
Most articles I read are concerned with building panels "on the cheap" as I did.
I built more than 300 watts of panels, all on plywood.
I will eventually need to somehow remove the Cells from the plywood and rebuild the panels on something more substantial, not sure what ( or how ) yet....maybe aluminium or Tedlar? Not a job I'm looking forward to but all part of a fairly steep learning curve.
Think outside the square and make Google your friend. A search of "solar panel backing" returned 98000 results including this one.. http://www.treehugger.com/files/2008/08/cotton-castor-beans-combined-solar-panel-bio-backsheet.php
My advice......research thoroughly then do it once and do it right.