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.
Step 2: Assembling the Solar Cells
Step 3: Creating Holes for My Connections
Step 4: Gluing the Solar Cells Down
Afterward, since I had two strings completed, I was able to go ahead and solder my bus wire on one end to bond the two strings of solar cells together. Watch Part 5 and Part 6of the video to see how I went about doing this. Note* after you solder any string together, or make new connections, it is a good practice to check the voltage/current that moment, rather than waiting until you connect all the solar cells/strings together. This is also mentioned in the video as well.
Step 5: Soldering Bus Wire
To help give the inside of the solar panel a nicer look, I used 2 strips of wiremold and ran the wires inside those. This is also seen in Part 7 and Part 8 of the video. Afterward, I took the panel outside in the sun to test the voltage/current of the whole panel to make sure I was getting 18 volts and 3.5 amps in an open circuit and short circuit.
Step 6: Visiting the Electric Side
Step 7: Adding Even Pressure on the Plexiglass
Step 8: Installing the Junction Box
Lastly, I took my silicon and went around all my edges of the solar panel, as well as the junction box on the back. Next I made a final voltage/current check and was ready to mount the panel to my roof.
Step 9: My Thoughts of the Whole Project
Overall, the project was a fun experience, and the total amount of money that I spent was around $400-$500, which includes the battery, charge controller, and deep cycle battery. So I saved a large portion by building my own solar system, since a commercial solar panel would have cost $400 on up for just the solar panel itself.
If you have any questions or concerns, just visit GreenTechTown.com's Forum and I or other members will try to answer them as quickly as we can. This is a free resource including the videos, so be sure to share this with others.
Boywonderg made it!