Since the primary voltage used in an automobile is 12 volts, the solar panel you build will most likely be of this rating.

There are a few items you need to purchase in order to make this project:

1. Solar cells
2. Silicon caulk
3. Aluminum frame
4. Perspex cover
5. 2-gauge wires
6. Soldering iron
7. A piece of substrate

You can either use broken cells or new/used ones. What I recommend (if you have the budget) is to use new PV cells. This is because you’ll get the most power. Since an automobile doesn’t have a lot of surface area, you need more power per square feet for your PV panel.

First, you have to position the solar cells on the substrate to make sure you’ve got your spacing correct. Next, check that the PV cells are orientated according to the correct polarity.

Once this is done, you can flip the cells and start soldering them. Use 2-gauge wires or tabbing wires so the electrical resistance is as low as possible. After this, put the cells under the sun and test to see if you’re getting the correct voltage and current output.

Then put the PV cells back on the substrate again. Row by row, put a blob of silicon caulk at the back of the solar cell. Then paste the solar cell gently on the substrate. Do not cover the entire cell with silicon caulk. Otherwise you will leave the material with little space for expansion and contraction. When sufficient stress builds up in the material (glass), it may crack.

You’ll usually have to wait at least 24 hours for the silicon caulk to dry completely. Otherwise it will leave deposits at the Perspex surface. This will hinder sunlight from entering the solar panel.

Immediately after pasting your solar cells, you may want to take some time to waterproof the solar panel frame. This prevents moisture and rain from entering your PV panel. Thus you’re protecting metallic connections and components from corrosion.

Finally, you can also build a small charge controller into the solar panel frame if space allows. However this depends on what you want to use your solar panel for.

Continue Reading:

1. How To Build Solar Panel (Part 2 of 3)
2. Step-By-Step Guide To Build A 12V Solar Panel
3. Building a Solar Panel Frame By Using Aluminum Angles

In general, climate has a direct influence on sunlight intensity. Different conditions (as listed below) may restrict or permit the use of solar panels on your property:

1. Sunlight.

The southwest part of the U.S. gets the most sun while the northern states (and Canada) gets the least.

Obviously if your area doesn’t have enough sunshine, it won’t be cost-effective to install solar panels. But how much is enough?

Studies show that the amount of sunlight we experience across the United States is more or less within 20% of the sunshine level in Florida. This makes it possible for most households to have solar panels on their roofs.

Occassionally, there may be shade issues at specific locations, but this can be solved in one way or another.

Generally, the more sun your home experience, the better (and faster) return you’ll have on your investment. You can get data about the sunshine your area experiences from the National Renewable Energy Laboratory (NREL). They recorded sunlight data on 239 locations all across the United States:

http://rredc.nrel.gov/solar/pubs/redbook/

2. Cloud

If you are living in a cloudy region, it is still possible to use solar panels. This is because solar energy is present although it’s diffused. Surprisingly, there is an advantage to this. The orientation of your solar panels becomes less important since light is coming from different directions.

3. Snowfall

Snow covers your PV panels and weighs them down. Some parts of your property may accumulate more snow than others. This may be because some spots are warmer than others. You will want to locate your solar panels where there is least snow accumulation.

4. Fog

Pollutants, fog and smog in the air affect sunlight intensity. If this is an obvious concern, you (or your contractor) should measure the sunlight intensity at your area to determine if you can get enough solar energy on a long-term basis.

5. Temperature

PV panels are affected by temperature. The lower the temperature, the better its performance. You can generally get more power output from a cold, cloudy day than a hot sunny day.

6. Air Density

Air density affects the amount of sunshine you receive. However its effect is marginal compared to the other factors. If you live on the mountains where air is thinner, you receive more sunshine. The air temperature may also be lower. Thus your PV panels will likely be more effective than when it’s installed at sea level.

7. Wind

Strong winds can damage your solar panel installation by tearing it from its mounts. But this, by itself, should not deter you from using solar panels.

To handle strong wind, you can either (i) use stronger mounts for your solar panels, (ii) use vegetation to block the wind, or (iii) use wind turbines to dissipate its force and to generate more electricity.

Some wind is actually good for solar panels. It helps to cool them down by bringing heat away. This helps to enhance its efficiency.

Continue Reading:

1. 7 Different Ways of Using Solar Energy At Home and In Your Office
2. Survey Your Household Energy Usage Before Installing Solar Panels
3. Before You Install Solar Panels, Plug All Your Air Leakages

Sealing Off A Crack

Before you install solar panels, you need to perform an energy audit.

This serves a two-fold purpose – to determine the size of your solar power generator and to identify sources of energy wastage that can be avoided.

As you are doing your household energy audit, it is useful to check for air leaks. They account for as much as 5 to 30 percent of your energy wastage (when it comes to heating).

If your windows and doors are closed and you feel an air draft, you have a good chance of cutting down wastage simply by plugging the leaks.

The best time to test for air leaks is when it’s cold outside and warm inside. You can feel cold air quite easily this way.

A pressure test can quickly surface any leakages around your house. All you have to do is close your doors and windows, turn off all heaters and turn on your exhaust fans to full blast.

In this way, the pressure inside your house is slightly lower than the outside. Thus more air will flow through those leakages to equalize the difference in pressure.

Go around the house and look for leaks. Pay more attention to windows, doors, electrical outlets, switches, hatches and joints. Once you find a leak, mark them out immediately.

Before you seal off those leaks, you have to turn off the exhaust fans.

You can use transparent silicon caulk to plug all your air leakages. The best way to handle this is to use a caulking gun that has a pressure relief gasket. This allows good control of silicon flow as you plug those leaks.

Another way to plug air leaks is to use an aerosol can of expandable insulation. This is difficult to use, initially, as it is hard to control its flow. But it works very well. So if it’s your first time using this, get some practice on used magazines.

There may be several places that leak air. Windows and doors are easy to handle. But if you have to climb up to your roof, remember to take precaution so you won’t risk falling.

After you’re done plugging up the leaks, repeat the pressure test. Then mark out those areas you have to work on again and get cracking.

You can also check for leaks outdoor. Most often, they appear in cracks, around faucets, pipes, electrical wiring and electrical outlets. Unfortunately there is no way you can feel for air leaks outside your house.

The only way to handle this is to do a visual inspection. If you suspect a leak, give that area a touch of silicon caulk.

After you are done plugging all your air leaks, your heating system can be more efficient. Thus your indoor temperature can be maintained using less energy.

Continue Reading:

1. About
2. Sizing Your Solar Energy Panels – Part 3
3. 7 Different Ways of Using Solar Energy At Home and In Your Office

How To Build Solar Panel

In this final part of the “How To Build Solar Panel” series, we’ll impart the finishing touches that make your solar panel project a winner. You’ll discover how to push your solar panel system up one notch so you’ll have a world-class DIY solar panel.

Here, I’m assuming that resources like money, time and skills are not lacking. What we’re trying to push for is a solar panel that will make you proud.

The Solar Panel Frame

The best material to use for the solar panel frame is aluminum. This is a material that will not rust easily and it’s able to carry away additional heat that may be trapped inside the solar panel. This is particularly important since heat can diminish the efficiency of the photovoltaic cells.

Diodes

The diodes you should be using are the Schottky types. These diodes have a much lower forward voltage drop so less power is wasted. And when the temperature gets higher the forward voltage drops further.

Solar Panel Cover

If budget allows and there is no hail at your area, the best cover that your solar panel can have is made of non-reflective glass. Solar panels covered with non-reflective glass can enjoy significantly higher efficiency because greater proportions of sunlight reach the solar cells.

Battery

If you intend to power outdoor equipment like sprinklers and gate openers, your battery will need to be sheltered from the rain and dew. Unfortunately it may be impractical to house these indoors as we’ll then need very long wires that may also be a safety hazard if it’s left lying around.

You can put the battery (or batteries) into a waterproofed electronics housing and seal up the opening (for the wires). In this way rain or dew will not cause short circuit to the battery.

By implementing all of the above tips to your solar panel project, you can surely make for yourself a world-class DIY solar panel project.

Continue Reading:

1. About
2. How To Build Solar Panel (Part 1 of 3)
3. How To Build Solar Panel (Part 2 of 3)

This is the third and final part of the “Sizing Your Solar Energy Panels” series. Have you done some calculations for your future solar power system yet? If you have been doing those mini exercises, you’ll most likely find a suitable solar panel for your home by now.

The next step requires us to find an appropriate-sized battery bank, inverter and charge controller. Let’s look at each of these:

1. The Inverter

The inverter you choose has to be sized according to the demands of the alternating current (AC) side of the circuit. Therefore you will choose a specification according to the loads in your house (with a little buffer in case you increase your loads over time). Pretty straightforward.

2. The Charge Controller

You’ll at least need a basic charge controller to begin with. Until you get fussy about how advanced you want this component to be, more affordable models will do just fine. You’ll need to get a specification that fits the output current (Amps) of your solar panel arrays. If you intend to scale up your solar power generator, you’ll do better with a larger charge controller with room to accommodate more solar panels than with two smaller-sized ones.

3. The Battery Bank

The size of your battery bank depends on how you want to use your solar panels. You can size your battery banks such that it can get you through thick clouds that pass by, or you can size them so you can get through three solid days of solar eclipse and a power outage at the same time. It really depends on you. But take note that over-sizing isn’t always realistic. You have to take into consideration the space they occupy and the how much they’ll cost you.

If your home is grid-tied, provided there aren’t frequent power outages, the size of your battery bank isn’t critical. Just size it to take care of cloudy days will do. You can still maintain your lifestyle by drawing power from the grid.

When you design your battery bank, you’ll have less power loss (through wires) if the voltage is higher. If you are able to design a 48-volt system, you can conserve more power than when you use a 24-volt or 12-volt system.

Continue Reading:

1. DIY Solar Panels — Charge Controller Basics
2. Sizing Your Solar Energy Panels – Part 1
3. Sizing Your Solar Energy Panels – Part 2

While you are working on your solar panels or solar heaters, you can also explore other small projects that can make your house a better place to live in.

Here are some projects that take you less than a day to implement. And many of them are very helpful in lowering your energy bills as well.

Most of them do not cost more than $100+, so if you have a little time and a little cash, you can begin right away:

1. Install solar screens

Solar screens help to keep your house cool during summer. It prevents heat from coming into your house through the windows. As such, your air-conditioners will not need to work as hard.

Most solar screens are quite affordable. The best ones are those with a metallic, reflective surface. They reflect radiation away instead of absorbing it. They are also pretty durable.

2. Solar ventilators

Ventilators can be installed at your attic, powered by solar energy. During summer, you can activate these fans to pump the heat out of your interior. This alone can cool your house considerably.

All you need is a small fan, a small vent that comes with a cover and a small solar panel. You don’t even need rechargeable batteries. It stops working when it becomes dark, but you won’t need it at night.

Try it.

When the weather gets colder, remember to cover them properly so heat doesn’t escape through these vents.

3. Solar powered air circulation

When you heat up your house, warm air rises to the top. They are all trapped at the ceiling or attic. Heat is not distributed evenly. You can install a ceiling fan to push the heat down, or use solar power to pump warm air down to ground level.

The effect: Your home warms us faster and you’ll feel more comfortable.

For this project, you’ll need a small solar panel, a set of rechargeable batteries, a long pipe and a small exhaust fan.

4. Landscaping

Planting trees, scrubs and bushes around your house can give you many benefits. You will not only create a beautiful and rejuvenating environment… You can prevent bitter cold winds from blowing against your house in winter and shelter your house from strong sunshine during summer.

5. Install solar light tubes

Solar light tubes allow natural light to enter your house while keeping the heat and precipitation out. They cost a little more. But you can experience the benefits of full spectrum lighting in your room without expensive illumination technology.

Continue Reading:

1. 7 Different Ways of Using Solar Energy At Home and In Your Office
2. Challenges and Difficulties In Using Solar Panels And How To Overcome Them
3. Survey Your Household Energy Usage Before Installing Solar Panels

Making A Homemade Solar Power System

When building and installing homemade solar panels, there is a fair amount of trial and error involved. This forms part of your learning curve.

There are also mistakes you might make that are totally avoidable. These “detours” can discourage you especially if it is your first time building your own PV panels.

Here are some common ones to take note of when you work on your project. When you avoid them, you should arrive at a good product that is ready to serve you:

Common mistake #1: Trying to build the solar panel frame first

We have to draft out a plan for your solar panel construction. However many of those plans, as we know, often require minor tweaks. At times (although quite rare) certain designs do not work at all. We’ll learn what these are as we start building more complex PV panels.

The way to build a PV panel is to adopt an inside-out approach. First get your solar cells together on your workbench, and then cut out the substrate. After you have mounted all the solar cells on the substrate, you are now pretty sure what the dimensions of the solar panel frame must be.

You’ll be left high and dry if you have completed the frame, only to find out later it is not deep enough to contain your solar cells. Also, there is no advantage in building the solar panel frame first. Thus you’ll save yourself a lot of (potential) trouble if you can build the frame only after you have mounted the solar cells.

Having said this, people who follow proven solar panel blueprints to the tee will not be susceptible to such mistakes. Yet this is a good habit to have, since you’ll sooner or later design your own blueprints, isn’t it?

Common mistake #2: Not allowing solar cells to expand and contract

Solar Cells Expand and Contract

Solar cells expand when it’s heated by the sun and contracts when it is cold. If there isn’t sufficient consideration toward this, your solar cells will crack after some time.

By then it is a great hassle to repair this damage. You have to climb up to your roof, loosen the mounts, bring down your solar panel, open it up, do lots of testing, etc.. You know what I mean.

One important thing you must do is to mount the solar cells on a just one blob of silicon caulk. If you spread the silicon adhesive on its entire surface, you leave no room for expansion. Thus the glass structure will weaken and crack after several cycles of expansion and contraction.

Common mistake #3: Sweating the small stuff

The fact is some of us are perfectionist. This quality, even though is good on some occasions, cause many to stop dead in their tracks while making a homemade PV panel.

You know you are one when you try to do these things before your PV panel is completed:

a. Trying to sort out small blobs of glue that overflow the joints
b. Filing off burrs at inconspicuous corners
c. Worrying about how to align your wiring

Fine details can really be sorted out later. In reality, there isn’t a mistake you make that cannot be resolved. After all, making mistakes are part and parcel of learning.

The best time to make adjustments and improvements is when you have more or less completed your project and have gained more confidence. Your DIY skills will also be more polished by then.

To save time (and effort), there are also many small little parts (like brackets and mounts) that you can buy from hardware stores or specialty stores. They do not cost much. If you make these yourself, you’ll not be able to spend more time on important parts of the project.

Common mistake #4: Not wearing a certified safety harness when installing PV panels

Many folks use a piece of rope or an old harness kept away for many years. BIG mistake. If you were to fall, the joy of making your own solar panels is totally robbed. The savings will also be entirely siphoned into your doctor’s cash-lined pocket.

Beg, steal or borrow…use a certified harness to keep yourself safe.

Continue Reading:

1. Insider Solar Power Generator Review: 3 Most Common Mistakes Hobbyists Make on Their First DIY Solar Panel Project
2. Have Your FREE Bonus eBook “How To Build A Solar Panel” Emailed To You Now:
3. Building A DIY Solar Panel – My Personal Experience

How To Build Solar Panel

In Part One, we’re going to take a look at the materials you need to build a successful project. In Part Two, you’ll learn how to put these parts together to form a complete system. Different applications certainly need different design considerations. We’ll cover how to modify your design to suit particular applications you have in mind. In Part Three, you’ll discover how to push your solar panel system up a notch so you’ll have a winner in your hands.

Before I go on to explain the different materials and components you need to build a solar panel, I must take some time to explain an important thought with you: you do not have to be an engineer of any sort to build a professional looking (and working) solar panel system.

You however need to know some basic soldering and this can be learned in a short span of 5 minutes…flat. You’ll also need to start your imagination engine so you’ll know how you’ll be using your solar panel to power your electrical devices.

In case you do not have any DIY skills at all, you can always buy ready-made solar panels complete with mounting brackets and connect the electrical wiring from there. This will be a little more expensive, of course.

Now, let’s look at the materials we need:

1. Solar Cells
2. Plywood
3. Jones Plug
4. Silicone Caulk
5. Super glue and screws
6. Diode
7. Plexiglass
8. Wires
9. Paint
10. Battery

Solar Cell

Solar Cells. Depending on your budget, you can either buy new cells or purchase slightly damaged ones. Yes, you can certainly put together broken solar cells. However if you’re not confident doing this, my best suggestion is to spend a little more money to buy new cells from eBay.

Plywood. No matter how small your project is, unless you’re very skillful with woodworking, you’ll probably need 3/8” thick plywood. A very good idea that I came across is to use a sturdy photo frame (metallic or wooden one) and work from there. At least you don’t need to put in too much effort for the solar panel frame. You can get plywood easily from your local hardware store.

Jones Plug

Jones Plug. This is a two-pin plug that terminates the end of the wires that comes out from the solar panel so you can plug this into your electrical system. You can find these at Newark Electronics or sometimes at eBay.

Silicone Caulk. This is a strong, waterproof seal that is used for fixing household items like our bathtubs and kitchen sink. Your local hardware shop sells silicone caulk.

Super glue and screws. Some super glue is useful to hold the pieces together before you screw them down firmly. Again, your local hardware shop probably sells super glue and screws.

Wires. It is best to get those wires that come in a twisted pair of red and black so that you can be very sure of the polarity as you solder up the wires.

Paint. Choose paint with UV protection so that it can protect against the continual UV radiation beating against the materials.

Diode

Diode. This component only allows electricity to flow in one direction of your choice. This is needed so that your battery will not be drained into the solar panel during the night or when the sky gets too cloudy.

Plexiglass. This provides a protective cover over the solar cells. Plexiglass has various advantages over glass – it doesn’t break easily and is much easier to handle.

Battery. One of the most important parts of the solar energy system is the battery. It ensures that electricity is available to your electrical application when there isn’t enough power output from the solar panel (probably due to a cloudy day or during the night).

These are the components you’ll need to put together a complete solar power generator that can supply a small electrical application.

In next part (Part Two) of the “How To Build Solar Panel” series, you’ll learn how to put all the above parts together. Till then, get your imagination engine cranking so you have an idea how you’ll want to put your solar generator to work for you.

Continue Reading:

1. About
2. How To Build Solar Panel (Part 2 of 3)
3. How To Build Solar Panel (Part 3 of 3)

You must use the proper wire size so electricity from your solar panels can reach its destination (like your battery bank) without severe loss of power.

A simple calculation will help you decide what wire size to use. A common standard for wire size is based on the AWG (American Wire Gauge).

Step 1: Decide on the voltage for your solar power system: 12, 24, or 48 volts

With lower voltages, you’ll require thicker wires. Recall:

Power = Current x Voltage

The power output remains constant. Therefore when voltage decreases, current increases.

Using thinner wires means you’ll have to spend less on cables. However this is not a great consideration if you do not have long cables to manage.

Do note that whatever voltage you decide on, the rest of your equipment (like charge controller and inverter) will also have to follow suit.

Step 2: Determine the maximum current (in Amperes) your solar panels will produce

You can get this figure from your datasheet. If you have built your own solar panel, you can first find out the maximum output current of each solar cell from its datasheet. Then calculate the resultant output current according to how you connect the cells together.

After you have got the maximum current rating for one solar panel, simply multiply it by the number of parallel-connected panels you have in the array.

Note: If you connect the PV panels in series, the voltage adds up. If you connect them in parallel, the current adds up while the voltage remains the same.

For example, if you have two 12-volt PV panels connected in series, the output voltage becomes 24 volts while the output current remains the same. If you connect these two panels (rated at 10 amps each) in parallel, you’ll get a current output of 20 amperes while its output voltage remains at 12 volts.

Step 3: Estimate the length of your cables

Estimate the distance between your solar panels and your battery bank (or wherever you want the cables to run to) in feet. Then add to this figure by another 5% to cater for loops and tiebacks, if needed.

Finally multiply this figure by 2 because one cable will run to the battery bank while the other will run back from the battery bank. (One positive and one negative.)

Step 4: Determine the allowable voltage drop across your cable

Power loss and voltage drops are unavoidable. For your initial calculation, you can simply use 3% as an estimate.

Eventually, you’ll have to use your voltage meter to measure the actual value across your solar panel array output and determine what’s allowable.

Step 5: Use the chart below to find out which wire you should use

First, you have to calculate the VDI value:

VDI = (Current x Distance) / (% Voltage Drop x Voltage)

Then compare this value to the table below to find the type of wire you should use.

For example, I have chosen a 24-volt system that gives me an output of 20 amps. My cables will run a total distance of 100 feet, to and fro. My allowable voltage drop is 3%.

Therefore my calculation will be:

VDI = (20 x 100) / (3 x 24) = 2000 / 72 = 27.8

Referencing the table below, I should be using a 2-gauge wire according to the AWG standard.

Note: Your max operating current must not exceed the max current ratings as stated in the table.

Continue Reading:

1. Sizing Your Solar Energy Panels – Part 2
2. Sizing Your Solar Energy Panels – Part 3
3. Homemade Solar Panels — Common Mistakes to Take Note Of When Building And Installing Photovoltaic (PV) Panels

Make Your Home & Office Clean & Green Using Solar Energy

There are many different ways of using solar energy. You can use it for heating, cooling and for generating electricity.

Each approach has different costs and complexity.

Here are 7 ideas how you can make use of clean, green solar power:

1. Generate electricity.

This is the first thing on everyone’s mind when we talk about solar panel. After all, we are all hoping to rely less on fossil fuel in the future. Using electricity generated from solar panels, you can power your household appliances and workstations in the office.

You can also store the solar generated electricity in rechargeable batteries to power up garden lights, floodlights, gate openers, garage lights, et cetera.

2. Passive space heating.

Instead of using electricity to heat up your house, the sun can do the work. You can trap heat in your home and office by using blinds, sunrooms and awnings. As simple as this sounds, it works very well to lower your electricity consumption.

3. Heat up air and water.

Your water supply can be heated up using solar collectors. Solar water heater do not require many moving parts other than the water pump itself.

Depending on your solar heater design and sunlight intensity, water temperature can be increased by as much as 10 to 15 degree Celsius. You can also increase your indoor temperature by letting a stream of air pass through solar heated water. This can be done using a simple heat exchanger.

4. Warm up food.

Do you pack lunch to work? If you do, there is no need to wait for your turn to use the microwave oven anymore. You can simply use solar energy to heat up your food at your own convenience.

5. Heat up your swimming pool

You can circulate swimming pool water through a solar collector. This helps you get lots of heat into your pool so you can enjoy a rejuvenating dip after you come back from work.

Another way to heat up your pool is to cover it with a solar blanket, which also prevents heat loss through evaporation.

6. Enhance your landscaping

You can use super-bright LED lamps as landscape lighting. This can save you the trouble of hiding cables under the soil. You may be surprised at how well these LED lamps bring out the color of your plants at night.

7. Water your plants

Solar panels can provide electricity to sprinklers that water your plants. You can build a self-sustaining garden by collecting rainwater underground and using them to water the plants at regular intervals during the day.

How else can you use solar energy in your daily life? Hopefully these ideas above can help you find your own ways of using solar power in creative ways.

Continue Reading:

1. Home Solar Power — Different Ways of Harnessing Energy From The Sun To Reduce Energy Bills
2. Survey Your Household Energy Usage Before Installing Solar Panels
3. Creating An Energy Efficient House – A Primer On Why You Should Do It and How