So to get started, I searched around and found a few videos here and there, and a few articles on how to go about building a solar panel, but it was hard for me to find a full free video or article that showed you the full process to making a solar panel from scratch. I ended up having to watch about 4 different videos, and then having to sign up for a forum to ask other questions I had in order to get a basic idea of how to go about building my own solar panel.
It was basically an adventure for me, and mid-way into the project, I decided that while I'm learning about how to build a solar panel, and putting it together, why not create a free video to help others that want to learn about solar energy and how to build a solar panel. Of course it takes time to edit the video, and time to create a website, but I see it as a small great way of giving back.
So, you'll learn how to build a 63 watt solar system in this instructable with free videos to help you get started. I know I'm a visual learner, so hopefully most find this very helpful.
For the full video series, simple visit my website at: http://www.greentechtown.com/how-to-build-a-solar-panel-diy
Step 1: Creating A Template & Putting Frame Together
Using a ruler helped to keep everything aligned, and it's easier to cut the plywood using a jigsaw, but a regular hand saw will do fine as well.
Next, once I finished my template, I started to put the frame together. What I used was a 1x2x8 piece of plywood, and cut that to fit my outer frame of the plywood. I wanted to make sure the outer frame was not too high to prevent from loosing any sunlight I could be using. So I then placed the pieces of plywood on top of the 2x4 pressure treated plywood, and screwed those down and sanded the entire frame afterward as seen in Part 2 of the video. After sanding and cleaning up any extra dust left over, I applied the Deck and Siding paint onto the frame. I wanted to give it 2 coats for a nice seal from UV rays, and making it water resistant. I also needed to place 2 coats of the Deck and Stain paint on the 2x4 piece of pegboard.