How to make a Solar

Panel
Be warned that it is expensive to do this kind of project,
make sure you have a considerable amount of money
before doing it.
 What is a Solar Panel and Solar Energy

By definition: Solar panels are those devices

which are used to absorb the sun's rays and
convert them into electricity or heat.

The sun rays we can call them as Solar Energy

Quote from Wikipedia, “Solar energy is radiant

light and heat from the Sun that is harnessed
using a range of ever-evolving technologies
such as solar heating, photovoltaics, solar
thermal energy, solar architecture, molten salt
power plants and artificial photosynthesis.”
 First Step: Purchase the Cells

There are a few different types of solar cells to buy,

and most good options are either made in the
United States, China, or Japan.

However, the best cost-to-efficiency option is most

likely polycrystalline cells. The number of cells you
should buy depends on the amount of energy you’re
looking to produce. The specs should be listed
when you purchase the cells.
 Information about buying the cells

Make sure to buy extras. These cells are extremely fragile.

Cells can most easily be bought online through websites like Tokopedia and Shopee, but
you may be able to purchase some from your local hardware store.

It may be necessary to clean wax off of the cells, if the manufacturer ships them in wax. To
do this, dip them in hot, but not boiling, water.

And lastly each cell shouldn’t cost more than $1.30 per watt.
Second Step: Measure and cut a backing board.

You will need a thin board made out of a

non-conductive material, such as glass,
plastic, or wood, to attach the cells to. Lay
out the cells in the arrangement you will use,
then measure the dimensions and cut a
board to that size.

Make sure to leave an extra space at both

ends of the board (around 3-5 cm). This
space will be used for the wires that connect
the rows together.
Step Three: Connecting the Cells

Glue the cells to the board. Put a small

amount of glue at the back-center of the
cells and then press them into place on the
board. The tabbing wire should run in a
single, straight line through each row.

Make sure the ends of the tabbing wire are

coming up between the cells and are free to
move, with just the two pieces sticking up
between each cell.
Solder the cells together. Apply flux to the
length of the two thick lines (contact pads)
on each cell. Then, take the free sections of
tabbing wire and solder them to the entire
length of the pads.

The tabbing wire connected to the back of

one cell should connect to the front of the
next cell in every case.
If you are building rows of solar panels

Connect the first row using bus wire. At the

beginning of the first row, solder tabbing
wire to the front of the first cell. The tabbing
wire should be about an inch (2.5 cm) longer
than needed to cover the lines, and should
extend towards the extra gap on the board.
Solder those two wires together with a piece
of bus wire that’s the same size as the
distance between the thick lines of the cell.
Step Four: Making a Panel Box

Measure your cell panel. Measure the space

taken up by the panel on which you have
placed your cells. You will need the box to be
at least this big. Add 1 inch (2.5 cm) to every
side, to allow space for the sides of the box.
If there will not be a free 1 inch by 1 inch
(2.5 cm x 2.5 cm) square spot at each corner
after adding the panel, also leave room for
this.Make sure that there is enough space
for the bus wires at the end as well.
 Continuation

Cut the flat back. Cut a piece of plywood to the size you measured in the previous step, plus the
space for the box sides. You can use a table saw or jigsaw, depending on what you have
available

Then Form the sides. Measure two 1 inch by 2 inch (2.5 cm x 5 cm) pieces of non-conductive
plank to the length of the long sides of the base of the box. Then, measure two more 1 inch by 2
inch (2.5 cm x 5 cm) planks to fit between these long pieces, completing the box. Cut these
pieces you have measured and secure them together using deck screws and butt joints.

Attach the solar unit to the box. Glue the solar unit to the completed box. Make sure that it is
secure and that the cells are facing up and can get sunlight. There should also be two holes in
the panel for the ends of the bus wire to go through.
Your Choice

Paint the box. You can paint the box

whatever color you prefer. Consider using
white or reflective colors since this will keep
the box cooler, and cells perform better
when they are cool. Your panel will last
longer if you use paint designed for outdoor
use. This type of paint will help protect the
wood from the elements.
Step Five: Wiring
Connect the final bus wire to a diode. Get a
diode a little bigger than the amperage of
your panel and connect it to the bus wire,
securing it with some silicone. The light
colored end of the diode should be pointing
towards where the negative end of the
battery goes. The other end should be wired
to the negative end of your panel.

This prevents energy from travelling back

through the solar panel from the battery
when it isn’t charging.
 Continuation

Connect the other wires. Connect a black wire to the diode and run it to a
terminal block which you will need to mount on the side of the box. Then
connect a white wire from the short bus wire on the opposite side to the
terminal block.

Connect your panel to a charge controller. Purchase a charge controller

and connect the panel to the controller, making sure to connect the
positive and negative correctly. Run the wires from the terminal block to
the charge controller, using color coded wire to keep track of the charges.

If using more than one panel, you might want to connect all of the
positive and negative wires together using rings, to make sure you end up
with two wires.
Use the batteries. Once you have the
batteries connected and charged from the
panel or panels, you can run your electronics
off of the batteries, depending on the
amount of power you need for them.
Step Six: Sealing the Box

Get a piece of plexiglass. Purchase a piece of

plexiglass that is cut to fit inside the box
that you made for your panel. You can get
this from a specialty shop or from your local
hardware store.

Make sure you get plexiglass and not glass,

as glass is prone to breaking or chipping
Attach block stops for the glass. Cut 1 inch by 1 inch (2.5 cm x
2.5 cm) blocks of wood to fit into the corners. These should be
high enough to fit above the terminal block but low enough to
fit below the lip of the box. Glue these stops into place using
wood glue.

Then insert your plexiglass. Fit the plexiglass onto the box so
that the glass rests on top of the blocks. Using the appropriate
screws and a drill, carefully screw the plexiglass into the blocks.

Seal the box. Use a silicone sealant to seal the edges of the box.
Also seal any gaps you can find so that box is as watertight as
possible. Use the manufacturer’s instructions to properly apply
the sealant
Step Seven: Mounting the solar panel

You can mount your the solar panel

anywhere there is sunlight

Ex: Mount your panels on your roof. This is a

popular way to mount the panels because
they tend to receive the most sunlight and
are out of the way.[29] However, the angle
will need to be consistent with the sun’s
path and your peak load time. This will limit
you to only getting full exposure at certain
times of day.This option is best if you have a
large number of panels and very little ground
space to place them on.
 End

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