Trying to build a photovoltaic panel without basic skills is akin to a man who tries to be a painter without knowing the basic techniques of handling a brush…or toddler trying to cycle without developing a sense of balance. It is bound to be difficult — at least initially.

There are 3 essential skills necessary to build your own DIY solar panels. They are (1) handling of tools, (2) soldering & (3) a practical knowledge of electrical circuits.

Knowing how to handle materials is important. Whether you build solar panels using wood or metal, you have to understand how to manipulate the materials to shape them into the design you want.

This implies you have to know how to handle simple hand (or power) tools. Then you can cut the material or bend them. You’ll also need to finish (polish) the surface and edges so the burrs and jagged edges can be removed.

Inside solar panels are row after rows of electrical connections that have to be made by soldering. Therefore you also need to learn how to use a soldering iron to bond metallic joints. Bad solder joints can cause unnecessary resistance in the electrical circuit, lowering the effectiveness of your energy production. Fortunately this is a skill that can be acquired easily – often within 15 minutes or less.

Having a good working knowledge of how electronics work can be helpful. You do not necesssarily need to design your solar panel from scratch, but you will need to know how to implement the circuit design recorded on paper. It will also be useful to know some elementary electronics formula so you can size your solar panel system. Again, this knowledge is easily acquired if you take some time to read up.

Basic formulae that are needed for building electronic circuits can be easily found on the Internet or in your local library. Moreover there are also many books on homemade solar panels in bookstores that can help you with these basics.

Equiped with the above DIY skills, you can be assured that building DIY solar panels can become a rewarding hobby.

Continue Reading:

1. Insider Solar Power Generator Review: 3 Most Common Mistakes Hobbyists Make on Their First DIY Solar Panel Project
2. Used Solar Panels – How To Use Them To Build Cheap DIY Solar Panels
3. Homemade Solar Panels

Wiring up all the solar cells in your solar panel takes about an hour or two. But if your solar panel is small and you are skillful, you can complete the task well within an hour.

Solar Cell

You’ll get better with practice.

Here is a list of things you’ll need:

1. Solar cells
2. Soldering iron & solder
3. Rosin flux pen
4. Silicon Caulk
5. 2 gauge copper wire

There are different types of solar cells available in the market. You will either see clear metallic lines or metal squares at the back of the solar cells. Both of these will work just fine.

What You'll Need...

When choosing solar cells, you have to make sure they are consistent. Which means you must use the same type of solar cells throughout the entire solar panel. This will keep things organized and make calculations easy.

Broken solar cells work fine too. But if it’s your first time building your own solar panels or if you want to generate serious power, avoid them. Stick to new or used (undamaged) solar cells.

Before you line up your solar cells, you must know how you’re going to solder them – in series or in parallel. You will have to orientate and organize the solar cells within your solar panel frame before soldering in order to avoid mistakes.

Solar cells connected in series cause the resultant voltage to add up. Connecting them in parallel results in a higher current. You must make sure your solar cells are connected so you end up with an array with your desired peak DC voltage and current.

When soldering copper wires to your solar cells, use the flux pen to help you achieve a good joint between the solar cell and the copper wire. This is especially important if the metallic surface is slightly oxidized.

After soldering all the solar cells together, test the voltage and current output.

Next, put a blob of silicon caulk at the back of each solar cell. Then attach them to the substrate and wait for the silicon caulk to dry completely before covering up the solar panel frame.

Notes:

• Many solar cells produce 0.5 volts (open-circuit) when exposed to sunlight. A 100 cm² silicon cell reaches a maximum current intensity of approximately 2 Amperes when radiated by 1,000 W/m².

• Some solar cells come with connection ribbons already attached. Thus you will have to solder them differently and ensure the leads do not touch one another to cause a short circuit.

• Heat from the soldering iron can cause burns and possible damage to solar cells. So rest it on the solar cell for only as long as necessary to make a good joint.

Continue Reading:

1. How To Build Solar Panel (Part 2 of 3)
2. Step-By-Step Guide To Build A 12V Solar Panel
3. Used Solar Panels – How To Use Them To Build Cheap DIY Solar Panels