How to Build your own Solar Panels

Introduction and How-To Guide.

By: CHRIS MCGRATH

Thrifty & Green: DIY Green Guide

There has been a lot of information and attention lately about building your own solarpanels. So we decided to investigate it and try to help our readers understand the different options available that one could implement. We mention in the February article Install Solar Hot Water and Save that the cost of purchasing a manufactured solar system be it water or electricity are quite expensive. Of course depending on the project we can be talking $5,000 to $10 or $20,000 of course directly related to quality, brand and how much wattage is needed. We illustrated in the previous article how with a little work, some basic carpentry skills and materials available both at the scrap yard or from Homedepot.com

Here we will attempt to show the some sort of introduction only with solar panels rather than a solar hot water heating system. Which of course work in harmony with one another. Solar panels are normally thought of by most as something you have to buy new and cannot make yourself. This is actually not really the case, in fact you can order the basic materials needed to build your own solar panels off the web for under a $100.00 for a about 80 solar cells. When your cells arrive get out the soldering gun and plenty of solder and your on your way. You will need a few other things.

Tool List

1. Soldering Gun
2. Solder
3. Hammer
4. Screw Gun
5. Skill Saw
6. Tape Measure
7. Pencil

Material List

1. Solar Cells
2. Solder
3. Light-Gauge Wire - for wiring together your cells
4. Plywood - for making a box to hold the cells or the "panel".
5. Plexiglas - for protecting the cells from the elements.
6. Aluminum Roof Flashing - for waterproofing around the plexglas and sides of your panel box.
7. Romex wire - enough to wire your panels together and to your battery pack.
8. Battery Pack - this is where you will store the power you generate.
9. Inverter - this will change your stored power from DC to AC.

This is the most basic system if you would like to connect to the grid and sell power back to your power company at times when you have excess power that will require a change of electrical panel and a larger investment. Here we will stick to the basic plan creating solar panels that connect to a battery-bank.

Step-By-Step-Guides

There are also a number of very comprehensive step-by-step guides out there. So we took a look at them and really found two to be more than worth the price. If your going to do thisinvesting in one of these would be a very good idea we highly recommend Earth4Energy, as they have a full unconditional money back guarantee and have been consistently rated the number one product. The package is actually amazing if you have any design/build experience. Both of the kits we recommend include full video instructions, transcripts of the videos, blueprints, and even a list of the cheapest and best sources to get the supplies you will need.

The other very good and a bit less expensive option was The DIY Energy Guide. They also offer a full money back guarantee if your not satisfied, and they will even teach you how to build them for others as a home-business, which we thought was a great idea. For a detailed overview of how to build your own panels -  

Basic Steps to Building your own Solar Panels

By: CHRIS MCGRATH

Guide

1. Solar Cells - So you ordered up your solar cells at around $1-$2 a piece. Now you are going to need is some batteries. The 12-volt lead or acid battery will do the trick. The type you are looking for here is a deep cell battery as they are built the best for constant and continuous use.
2. Panel Box - Now you will need to build your plywood or if somehow you have a metal shop sheet-metal box that will hold your bed of cells.
3. Battery Box - In order to build your solar panel safely should build or buy a battery box. This will protect you and the kids from batteries and the power they generates.
4. DC meter - that matches the voltage of your battery configuration and a DC input. These products will allow you to convert your energy from the panel and apply them to power sources around your home. Of course if you are hoping to power AC appliancesyou will need an inverter as well. They are available at any Home Depot or electrical supply store.
5. Solder Cells - get some video instruction here and connect your solar cell array together.
6. Wire it Up - Use a hand held drill to attach your meter and DC input to the top end of the battery box. Next use some insulated wire to connect the meter to the battery.
7. Connect it to the Battery Bank - Remember safety first, be careful to only work with one wire at a time and connect the first wire to the negative input first. Use the same procedure to connect the DC inlet and the solar panel to the battery itself.
8. Seal Panel Box - cover the panel box with your plexiglas and then trim it out with the aluminum flashing put the entire product out into the sun.

Several hours later (sun willing) you will have a fully charged battery bank. You should contact a licensed electrician or at least your neighbor the electrician to help you connect your battery bank to your electrical panel. As we said earlier being able to sell power back to your power company requires a much larger investment and involves purchasing a new electrical panel which are pretty pricey. We will be producing future articles that delve into this but for now to establish that it can be done fairly easily and the claims are true. You can build your own solar panels for under $200.00 a piece.

Don't forget to check out the other articles in the Thrifty & Green: DIY Green Guide while you are here.

Source: http://www.thriftyandgreen.com/content/build-your-own-solar-panels

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How To Build A Solar Panel And Solar Power System, Second Edition:

5.0 out of 5 stars Very Useful Resource, March 9, 2011

By 

Mackenzie Adams - See all my reviews
(REAL NAME)   

This review is from: How To Build A Solar Panel And Solar Power System, Second Edition (Kindle Edition)

This was a very worthwhile read. I'm amazed by how simple the instructions were, and the author provided a lot of photos which really helped me get an idea of what the different parts and steps should look like. Unlike some of the resources I have used, it wasn't difficult to understand the technical terms, even with all of the new information that was being presented to me. After following all the steps, I really feel as though I know more about solar energy and it feels great to push for clean, green energy that will pay for itself over the next few years. 

I would highly recommend this book to someone who is new to solar energy in general(like I was), and is looking for a great do it yourself solar panel guide that is easy to understand and straight forward.

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