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I have made wood frame solar panels and all glass solar panels, but so far out of all the solar panels
this type of DIY solar panel is the most sealed from water.  I have made wood frame and all seem to get moisture in them. I still make them but they are good under a roof or eve .
This diy solar panel was made with all cracked 3"x6" solar cells to see if I could get the same power out of them, on the next steps I will show what all I did. http://sites.google.com/site/earthforsolar/glass-frame-diy-panel

looking for solar cells www.solarcells101.com

Step 1: soldering tabbing wire on solar cells

When I solder the tabbing wire on solar cells I cut all the tab wire first. If i am using 3"x6" solar cells,
I will cut two pieces of tabbing wire 6" long.  Then I soldered all the backs first. http://sites.google.com/site/earthforsolar/glass-frame-diy-panel
On this set of solar cells I used cells that were cracked all the way across, I soldered the tab wire on the back first then I used packaging clear tape and taped the bottoms. This made the cell stronger and helped to keep them from braking more in the soldering and diy solar panel making process .

www.solarcells101.com


<p>What about plexiglass instead of glass? Should not be more impact resistant and maybe lighter?</p>
<p>I have a 76 -46 glass and want to make a solar panel my system is a 24 volt off grid system I want to use this glass but I can fit 84 6x6 cells on it and I want to keep it at 30 volts .Question is can I hook them in series up till 30V then parallel for the remainder of cells </p>
<p>From experience... Don't bother with wood. No-matter how well you try to seal it, weather will find a way in. The sun will crack it and the rain will absorb in, swell the wood, warp the frame enlargen the cracks and then the water will get in and rust the wiring. The best things to use are aluminum frames (make or purchase), 1/4&quot; hardened (tempered) glass, and proper solar encapsulant flooding material (buy on eBay). My two wood panels I have had to seal the cracks with epoxy and repaint every year to keep them from being destroyed. It's just too much work!</p>
<p>Now if you could do this and somehow leave a hole on top and bottom and then pump the whole thing full of a proper solar encapsulant mix so the air is sealed out and the cells are protected from oxidation and water intrusion, it would be an even more reliable panel over the long haul.</p>
DIY Solar Panels are the only way to think about...<br> Because Commercial Panels as so expensive<br> It will take you 10 years to break even on commercial solar panels<br> Look at this <a href="http://topdiysolarpanels.com" rel="nofollow">diy solar panels website</a>&nbsp;that calculate it<br> &nbsp;
<p>This is no-longer true. Commercial panels can be had for about $1 per watt on eBay (and that can go lower if purchased in bulk on a good auction!)</p>
That website is a scam selling books and videos. Don't trust his characterization of prices, just shop around and decide for yourself. <br> <br>Some things to consider about DIY panels: <br> <br>Have you ever built one? Is it as easy as they make it look? (Most solar cells are extremely fragile and you will break a large percentage of them to build your first panel. They are about as durable as a potato chip. Imagine trying to solder to that.) <br> <br>Exactly how much/many solar panels would it take to take your household &quot;off the grid?&quot; (Think square footage. It's a lot. It will take a lot of KW to get to the point where you are independent of the electric company or can actually sell back to them.) <br> <br>How durable will your DIY panels be? Will they work in a year? Five years? Ten - twenty? Or will you be climbing on your roof to take them down to work on in the middle of the winter? <br> <br>Even if you can do it, will your DIY panels work in a grid-tie system? Will they pass electrical inspection? Are they safe? Can you get the tax rebates without documentation provided with the commercial systems? Will your homeowners insurance cover the panels, or you home, if there is an electrical fire? <br> <br>DIY panels are a great project for the cabin or motorhome, but if you are looking at them for your home, there is a lot of hidden costs to consider before deciding commercial panels are too expensive. The electric company isn't keeping secrets about solar power from you. It's not a conspiracy. It's just economics. <br> <br>The price of commercial panels has been coming down and the conclusions the fellow has drawn in the video website are out of date. Today, in many areas, you can have a company come in, install a commercial solar-electric grid-tie system in your home and the savings and power sold back to the grid will pay for it. They can do it with nothing out of pocket.
Curious... With two sheets of glass like that, do you have any issues with heat? Is your output still good in the middle of the day?
Condensation is going to be a big problem. Unless you can make a vacuum there is no way you will stop it, and we all know water and electricity do not mix. <br>I have made the same panels as you but put them in an aluminum frame on top of 4mm toughened glass. I've then encapsulated them in clear epoxy resin. Have had them on the roof for over a year with no problems so far.
Nitrogen gas filled will stop the condensation
I heard you couldn't use epoxy because it doesn't have enough give which will cause the cells to crack when they contract or expand with seasons or day/night changes...... But after a year, you see no damage to the cells??
On your site what would be the best deal of solar cells so i can make a panel

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Bio: I love solar energy and building homemade diy solar panels, that is why i put together a solar diy free E-Book at sites.google.com ... More »
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