How To Build Solar Panel

In this part of the “How To Build Solar Panel” series, you’ll learn how to put the different components together. Hopefully you’ve already got an idea what you want to use your solar panel for.

We’ll use a 12V DC automatic door opener as an example…

To power an electrical system that runs on 12VDC, we need a 12V battery. I’d prefer using one of those maintenance-free batteries as compared to troublesome lead-acid types. And in order to charge the 12V battery, we’ll need the solar panel to generate about 18V. (It needs to be at least 5V above the battery voltage)

Connecting the Solar Cells

Each solar cell produces 0.5V. To get 18V, we can join 36 solar cells in series. Assuming the solar cells are of the same quality, a larger solar cell will produce more current and thus more power.

You should always ensure that the power generated by the solar panel is sufficient to charge your battery. Otherwise you may have to join more cells in parallel.

If you want to connect the solar panel directly to your appliance, you can simply make-do with 12V output from the solar panel. This is however not advisable for most applications…unless you need your appliance to work only when the sun is out.

Constructing the Solar Panel Frame

Next, we have to create a shallow box (as solar panel frame) for the solar cells to sit in. The borders of the box should be about ¾” wide by ¾” high. If this too high, it will cast a shadow on the cells as the sun comes in from the side. If it is too low, it doesn’t allow sufficient clearance for the solar cells.

Before you screw the pieces of plywood together, you can first hold them together by super glue so they’ll stay in place as you turn in the screws.

Putting the Array of Solar Cells Into The Solar Panel Frame

To get the solar cells into the solar panel frame, glue the array of solar cells onto a thin, rigid backing before placing it into the “box”. An example of this thin, rigid backing is a Masonite board.

We should give the rigid backing a few coats of paint before pasting the cells on. We must also apply a few coats of paint to the panel frame and dry it thoroughly before putting in the array of solar cells.

Connecting the Diode

Connect the diode at the power output of the solar panel. You should locate this inside the solar panel and hold it down using some silicone caulk so it won’t move about.

Placing the Plexiglass Cover

Before covering the solar panel with the plexiglass cover, test again to see that you’ve got the correct voltage and power output. Then carefully drill the holes (for the screws) at the border of the plexiglass.

Take care to apply moderate, consistent pressure while drilling so that the plexiglass won’t crack. Also remember to countersink the hole so that you can flush the screws with the surface, if necessary.

Attaching the Jones Plug and Battery

At the end of the wire that dangles out of the solar panel, attach the (male) Jones plug by soldering them on. Also solder the female Jones plug to the battery terminals according to their polarity.

Using a connector like a Jones plug makes it convenient for you to disconnect the solar panel from the battery if you need to.

And after hooking up the parts in the above manner, you’ve made for yourself a complete solar power generator that can power up your electrical gadgets — anything that runs on 12V.

In the third and final part of the “How To Build Solar Panel” series, you’ll discover how to “tweak” your solar panel system. You’ll inevitably end up with a world-class DIY solar panel running on steroids!

Continue Reading:

1. How To Build Solar Panel (Part 1 of 3)
2. How To Build Solar Panel (Part 3 of 3)
3. Step-By-Step Guide To Build A 12V Solar Panel