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Currently I'm a college student studying computer engineering, and this summer while I was on break I decided I wanted to learn more about solar energy and how to build a solar panel from scratch. My main reason for looking to build it myself was to learn how it all worked, and the next reason was due to the price of a commercially built solar panel.
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.solartechtown.com
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.solartechtown.com
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Signing UpStep 1Creating A Template & Putting Frame Together
First, I want to make a template for my solar cells. What I used was a spare piece of regular plywood, a piece of regular cardboard the size of a solar cell, some tile spacers, and a staple gun to create my template. I wanted to use the tile spacers to help keep my solar cells even as seen in Part 1 of the video.
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.
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.
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Maybe using ABS Sheet or something that doesn't get wet nor melt may be better, but you should know better. Another thing I also wanted to ask you sir, is if you recommend those diy guides like the one in this Earth4Energy Review, because they seem pretty cool and easy to follow.
Thanks and keep up the good work.
plz let me know on my email id :
rohitbhl@yahoo.com
If you are camping, you should make the panel attached to the roof but still removable. That way, if you would rather camp in the shade, you could set the panel up in the sun with a cord running back to the van.
It sounds like a really fun project.
http://sunelec.com/Solar_Array_guide.pdf
I looked at your website and you posted a spreadsheet on the cost of producing the panel. Your list of materials includes the tools. What is the approximate cost if I already have all the tools?
For my solar panel I did not buy any tools, such as the power drill, saw, and other power tools. I also had all that on hand already, and the spreadsheet doesn't include those items.
Maybe you are referring to something else?
PAUL COX
POOLE, SOUTH COAST ENGLAND.
Since the whole back side is conductive, can you solder anywhere on the back?
Thanks
Robert
You don't have to solder the tabbing wire on all the white spots, but it does add a better bond in the rare case one part of your tabbing wire was to come apart.