Homemade Solar Panels Pt 2: Panels

This probably seems like an even bigger pipe dream that putting your own solar array together- actually building your own solar panels. However, the technology for converting the sun’s energy into electricity has undergone rapid development, making it much more accessible to the home builder.  

Maybe the greatest advantage to this is the same reason I fix my own car and bicycle- knowing how your solar array is constructed teaches you how to maintain and repair them if damage ever occurs. If you live in an isolated location, this is particularly helpful. If you don’t, it’s still helpful when you consider both the sense of satisfaction you will gain out of doing the project yourself and the money you will save if anything does break and you can fix it yourself.

Furthermore, apart from batteries, no piece of a solar power system is particularly heavy. Lastly- mounting the array doesn’t require any specific equipment or advanced knowledge of electrical systems (which seems counter-intuitive, but it’s true).  

The materials are easy enough to access, but there is a wide variety of solar cells that may confuse the novice. Photo-voltaic cells are the easiest to work with and are cheap. Avoid “B-grade” cells- or those that are wax dipped.

In addition, be careful to vet your supplier before buying by checking reviews. Some discount suppliers, particularly those operating out of China, have cut their prices by cutting corners.

Most of the rest of the supplies you will need are probably in the workshop of any DIY enthusiast. You will need:

1. A Hammer
2. A Saw
3. A Soldering Iron
4. Screw Drivers
5. A Paint Brush

In addition, you will need a frame for mounting the panels on the roof. To make a frame, you will need some wood, some screws, and black paint.

To cut down on the boring nature of the project, get pre-tabbed photovoltaic cells and the tab wiring to connect them. This saves on the wire stripping and cutting. Get some eva gule, solder and flux, plastic sheeting to cover the housing, and some blocking diodes to stop the current reversals and you’re on your way.

Begin by building an outer housing and sealing it with silicone filler. Glue the cells to a board in a 6 by 6 square with the tabs up. Join the tabs with solder and tab wiring, adding the blocking diodes to stop current reversal when the unit isn’t getting enough power from the sun.

With the panel in the housing, cover it with the plastic. Get the roof frame ready by painting it black to help with head absorption.

Mount the solar panel on the roof housing and connect to your tie-in.

Congratulations! You just built a home solar power system!