If you want to save money and gain some insightful knowledge into electrical engineering, then you have come to the right place. Store bought solar panels tend to be expensive to purchase and install. In this article, we will teach you how to make a solar panel all by yourself. It is not easy, but with some hard work you can have an assume new solar-powered product.

how to make a solar panel: how to make a solar panel

Building your solar panel from scratch can be both an exciting project and a useful undertaking. Homemade solar panels help you save money on your monthly electricity bill. What is more, they reduce the strain on the environment from greenhouse gas emissions and waste. Not to mention the money you
save when you do not buy an expensive mass-produced model. So where do you begin? First, you are going to need a list of material. Here is everything you will need for this project:

  1. Standard plywood board
  2. Flux Pen
  3. Polycrystalline solar cells
  4. Tabbing wire
  5. Smoldering wire
  6. Soldering gun
  7. Silicone Glue
  8. Jigsaw
  9. White paint
  10. Charge Controller
  11. Battery
  12. Silicone Sealant

When purchasing solar cells, it is generally a wise precaution to buy more than you think you will need. These solar cells are incredibly fragile, and they may break during shipping or construction. You can apply however many panels to your board that you can reasonably fit. This setup will determine how many kilowatts of energy your panels manufacturers. Now let us get started on figuring out how to make a solar panel.

Step One: Construct a Background for the Solar Cells

Layout the board on the ground and place the number of solar panels you need on to them. If you want you can also use plastic or glass, but the glass is hard to work with because you need to cut it. Make sure that there is an inch or two around the board for wires. Next, you will need to measure the appropriate length of tabbing wire. This wire will be used to connect the solar panels from behind.

Next, use a flux pen along the length of the front side of the cell dividing each cell into three squares. This pen will prevent oxidation through heat. Next, melt a thin strip of soldering iron onto the back of the cell. After this step, you should use the soldering iron to bond the tabbing wire on to the end of each solar cell you are using.

Step Two: Placing the Cells on the Background 

The next step is gluing the cells onto the frame of the solar panel. Place a small amount of silicone glue on the back of each group and position it so the two tabbing wires come out evenly and can move freely. 

Try and put the cells in long vertical rows instead of horizontal ones. Drill holes at the at the end of each connection area with the tabbing wire. This process will allow the cables to pass through.

Next, you will need to solder all the wires together, so they are all connected — starting from the front of the back one and ending on the back of the front one. Once you complete this step, then join the first row of cells to the smoldering wire at the end of the row. Repeat this process for each row, attach the end of each with the smoldering wire

Step Three: Construct a Frame for the Panel

One the board with the glued on cells, use a pen to measure the space around the side of the cells. Then, use the same marker to mark another rectangle one inch across from thing one — outlining the frame. 

Once you describe, then you should cut off the excess board with a jigsaw. Next, measure out planks that are one inch by two inches. Cut these pieces along the side of the background panel and place the frame out wood around the board. Use the screw and a drill to connect the structure to the background panel with silicone glue.

If you want, you can paint the frame color at this point. We recommend the color white because this is a cooler color that will help not overheat the panel.

Step Four: Wire the Solar Panel

Use the bus wire that connects all of your cells and attaches it to a diode. Make sure the negative side of the diode is attached to the positive charge of the busing wire. This process will turn the wire into a negative charge and ensure energy travels back when it is not running. Now, connect the other positive black cable to a diode and secure the connection a terminal block. Make sure you achieve the white wire behind this terminal block.

It is now time to hook your panel up to the charge controller. Secure the charger on a wall or similar stable surface and run the wires from the terminal block on to the charge controller. Connect the cables to the charger and make sure that the black positive charge goes into the real port and likewise for the white negative charge into the negative port. If you are making multiple panels, then you will need to write them all together before connecting them to the charge controller.

Next, you will need to connect you charge controller to the battery. This process will charge the battery and allow you to use the energy. Once the sun costs the batter, you can then run it off to your other electronics that need them. Like your fridge, cars, or pools

Step Five: Seal off the Frame

Now that you wired everything up correctly, you can seal of the frame with a piece of plexiglass (It is essential that you use plexiglass and not regular glass). You need to seal the shell off in case it rains. The solar panel connection cannot get wet, or it will ruin the electronics.

Make sure you cut the plexiglass specifically so it can fit within the inside of your solar panel frame. You can get this process done at most hardware stores. Glue four separate wood blocks on the corners of the frame, so the cells separate themselves from the plexiglass. Drill the plexiglass into the frame and use a silicone sealant to waterproof the edges of the glass

Step Six: Install the Solar Panel on a Mount

It is now time to mount your newly utterly solar panel - the last step in how to make a solar panel. You can attach your board one of three ways. The way you install your solar panel depends on where you live and what you are comfortable doing.

The most popular option of mounting solar panels is on the roof of your house or building. This method is so popular because the roof usually gets the most amount of sunlight. Solar panels can be cumbersome and installing them on the roof can be dangerous if you buy yourself so make sure you get help from someone else. If you are connecting your solar panel on the rough, then make sure it is at a right angle on the house. If you do not do this step, your solar panel will miss out on half of the days light.

If you are not comfortable going on the roof, then another option is just using a wagon or cart to prop up the solar panel. While this method might seem simplistic, it is quite smart because you can move the group to sunny patches of your property when the time of day shifts. However, keep in mind that this will require you to run the wagon or cart two to three-time every day.

The last available option is to mount your panel on the back of a satellite stand. This option allows you to move and rotate the solar panel throughout the day, like the wagon or cart. If you feel like going all out, then you can purchase a satellite stand that moves throughout the day. This process allows you to program the solar panel to follow the path of the sun. None of these methods is better than the others, but
depending on your living situation some might work better than others.

All together this solar panel costs around one hundred to two hundred dollars to make, excluding equipment like power tools and glue. Make sure you are careful when wiring the solar panel, especially when you are dealing with existing connection wires.

We hope this article has been helpful during your construction project. Learning how to make a solar panel is by no means a natural process. It will likely involve a lot of head scratching and troubleshooting, but with perseverance, you can succeed. But with the right trial and error, you could be the talk of the town with your function solar panel. Take pride in the fact that you constructed a complicated piece of
equipment and you saved a lot of money by doing it.

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