Solar Cell Panels: DIY Instructions

Make the Solar Cells

• 1

  Select a non-conductive backing material for the solar panel, such as plywood, Plexiglas or acrylic. Plexiglas or acrylic last longer and make the task of cutting easier. Cut the material to the correct size. The measurement depends on the number of solar cells for the panel.

• 2

  Apply at least one coat of ultraviolet paint on a plywood backing. The coating protects the material from deterioration due to the sun, water or other elements. Mark the location of each cell on the backing material.

• 3

  Connect the solar cells into arrays. Start by laying the cells out in four rows with single lines containing nine cells (or the number for panel size). Use ¼-inch tile spacers between the cells. Allow a ¼-inch space between the cells and the backing edges. Align the tabs on the solar cells in the same direction. Position the solar cells so that the tabs on the top cells run under the adjacent solar cell. Repeat this pattern down the entire length of the panel.

• 4

  Solder the cells. Apply the flux to both tabs. Overlay the tabs. Use the soldering iron to connect the tabs together. Connect the bus wire long enough to span across two tabs on a single solar cells. Apply flux and solder. Use the soldering iron to connect the bus wire across the two tabs. Identify the positive and negative wires at the end of the panel.

• 5

  Test the solar cell to make sure the connection works properly. Face the cells toward the sun. Attach the multimeter to the positive and negative terminals of each cell. The voltage should read 0.50 to O.55 volts for each solar cell in the array. Four arrays with nine cells each should yield a reading of 4.5 to 5.0 volts when testing the panel.

Connect the Cells

• 6

  Arrange the cell arrays on the backing material so that each array has the opposite polarity of the array adjacent to it. For example, if the bottom of an array is positive, make the array adjacent to it negative.

• 7

  Place the solar cells with the back facing up. Apply a small amount of silicone adhesive to the center of each cell making up the array. Turn the cell array on the right side. Position the array on the backing material. Work carefully to avoid smearing the glue or applying too much pressure, which could damage the solar cells.

• 8

  Wire the cells in a series to combine the voltage output. Connect the negative wire of the outside solar cell array to the positive wire of the adjacent array. Wire the positive wire of the outermost array to the negative wire of the adjacent array. Continue this wiring pattern. At the end of the process, you have two remaining wires.

• 9

  Solder two insulated wire to the two terminals. Construct a wood frame. Use metal framing material for plastic backings. Drill a hole in the side of the panel. Pull the wires through the hole. These wires lead from the panel and provide a primary connection for the panel. Cover the panel with a sheet of Plexiglas. Secure the Plexiglas with silicone caulk.