First, it is best to determine the output you want to achieve based on the size, type and number of individual cells you are using. Then you simple build a very shallow frame with a panel in the center onto which the connected solar cells are installed. The entire assembly is enclosed on both sides to keep the weather out.
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Panels are usually built from wood, aluminum, PVC pipe or a combination of these materials. I’ve even seen small panels put together with cardboard and duct tape, but obviously, these won’t stand up to outdoor environmental conditions. Build your frame as thin as you possibly can. You don’t want to create a thick profile that could shade any part of the interior cells during times of the day when the sun is not directly overhead.
The best way to achieve maximum efficiency in any solar panel is to have as many of the cells exposed to direct, {prolonged|perpendicular} sunlight for as many hours during the day as is possible.
So then, you can use a field panel of three eighths inch plywood or OSB and surround it with a frame of three quarter inch stock. I’d like to point out we prefer plywood for the inner panel because no matter how well you seal the finished unit, there is still a chance for moisture to get through and particle board can act like a sponge.
Once the cells are all properly soldered together, the array is installed on the inner panel. The wiring will have to extend outside of the frame so that the final product can be joined to the appliance orelectrical system you want it to run. Use plexiglass or EVA (Ethylene vinyl Acetate) to encolse both sides .
Starting with a 2 ft x 4 ft frame, you can easily install 3 rows of 12 individual solar cells that measure 3 inches by 6 inches each. Depending on your skill level and the tools you have on hand, you could float the inner panel in the frame and create an simple outer moulding for securing the plexiglass lens. However you do it, it bears repeating that it is very important that the unit is properly sealed to keep moisture out and to protect the connections between cells.
Before you start, do yourself a favor and pick up one of the good written guides which contain detailed step by step instructions. Be cautious because most of the guides on the market are junk. A good one can save you a great deal of time and money too. While its a pretty simple process overall, you can’t just learn how to build a solar panel and be done with it. There are sizing and connection issues to plan for and doing this up front avoids a lot of do-overs and headaches. You can get a lot more information on how to build a solar panel and see our full reviews of the best guides at our site.
