Build Solar Power pt 1: Array

Putting together your own solar array- seems like a pipe dream right? Solar panels are complicated pieces of equipment that are sold for thousands of dollars. No way can you build one at home. But alas, that’s one of the best kept secrets of solar panels. You can find or buy the materials- sometimes even in a kit. It’s extra-cool- you can look out and see that YOU built that whole solar array from scratch- and it’s a lot cheaper.

Building a solar panel requires a few tools before beginning the job. Most will be lying around: you’ll need a hammer, saw, screw drivers, knife, and a soldering iron (which you should probably have if you’re going to get serious about green power). The materials you’ll be putting together are more extensive. However, the biggest (by actual size) materials you’ll need will be the mounting materials for the solar cells. Fortunately, you can choose to be creative with this, building it out of wood you have lying around the house.

What to look for online is as follows:

1. Pre-tabbed photo-volatic cells (solar cells)
2. Tab Wiring (connects the cells together)
3. Eva Glue
4. Solder
5. Flux
6. Plastic Sheeting

Once you have those materials, construction can begin (bearing in mind that other materials will be needed, depending on your power storage decisions).

Now- sit back, look out at your property, and think about where the sun shines. Make some decisions on where to locate the solar panels. Some people will simply choose the roof- it’s a convenient location. Others will build a rack for them elsewhere on their property. The best site will be south facing (gets the most sun) and is at least a 30˚ slope. Also- it needs to be convenient enough for you to wire to the house or battery packs.

Solar panels should be put together in a clean, dust free space. It is essentially an assembly project. The cells are fixed to a backing board in 6x6 row (usually). 

Once the panels are mounted to a backing board, the following steps will get the system up and running:

1. Join the cell tabs with tab wiring
2. Add blocking diodes and cable to connect to the grid or batteries
3. Cover with a plastic lid
4. Seal the unit with silicone grouting
5. Mount the unit

If mounting on the roof, some insulation should be applied to the rear of the housing. If nothing else, these units can get hot. It can be insulated with appropriate paints, plastics, or my personal recommendation, white PVC sheets (although this is a bigger investment).

Putting the thing on the roof is really a two person job. The solar cell is heavy and awkward, and it could be dangerous to be on the roof working with this.

If mounting elsewhere on a pre-designed stand, then this should be a much easier project.

Bear in mind that you don’t need to be a survivalist or a construction foreman to build your own solar panel. It should be fun and interesting to construct your own solar panel. If you don’t think you can do it from scratch, consider buying a kit or a complete solar panel unit.

Earth4Solar also has a good guide on building your own solar panel from scratch.

In any case, this project should be fun and interesting. If it’s too scary, find another way- but don’t let that dissuade you from building your own solar panel. You can do it- and it will be fun.