How to Build Your Own Solar Panel

Having a solar electric system installed by a company is expensive, so many people prefer to buy DIY kits, or to build their own. 

For those that are not daunted by technical details, the task of building a DIY solar panel can be completed in a very short time. Solar panels can be easily constructed using parts obtained through Amazon, eBay, or from the local hardware store.

The most expensive component of a solar panel is the solar cells, which are made from crystalline silicon and conducting metals that convert sunlight to electricity. 

To save costs, blemished or damaged solar cells in working condition can often be picked up at a much lower price than the cost of cells that are in perfectly new condition. 

A total of 36 3’x6’ solar cells will be required for a complete solar panel (other sizes are available and can be used, just make sure you buy cells of uniform sizes and wattage). 

The cells should be wired in series by soldering, leaving some space between the cells to allow for expansion when they are heated by the sun. 

Normally each cell will generate roughly 0.5 volts, so 36 cells in series will produce around 18 volts, which is sufficient to charge a 12 volt battery. 

Other equipment that is necessary to complete the system include: an inverter to convert the DC current of the solar panels to AC current used by household appliances; deep-cycle batteries to store surplus energy; and a charge converter to ensure that batteries are not overcharged, or excessively drained. 

Once the solar cells are wired together in series, they are attached to a backing-board and secured in a protective box casing built to house your solar cells. 

This must be shallow enough to allow sunlight to reach the cells without being inhibited by the sides. 

The front of the protective box casing is covered with a durable clear plexiglass front to protect the unit from the weather. 

You’ll need to weatherproof your unit by sealing the joins with silicon and painting the backing board if you’re using plywood.