If you are already a bit of a handyman, learning how to make solar panels is just a matter of details.
The technology required to build a solar cell is beyond the reach of the average homeowner. The technology required to connect solar cells and house them in a durable solar panel is much simpler. Durability is the most important criterion for solar panel materials. Some types of solar cells are quite delicate, especially first generation silicon cells. If the backing material or frame of your homemade solar panel warps too much, you could end up with broken cells. Ideally, you should mount cells on your frame in a way that allows for some frame distortion without putting strain on the connections or cells. Most instructions recommend a 1/4 gap between cells. Lumber and plywood may be the cheapest materials and they are easy to work with. If you choose to use wood, it is absolutely vital that you carefully apply a weather seal finish to all surfaces. Aluminum sheets and framing materials are more durable, but also more expensive. You may also find yourself shopping for some new tools if you go that route. Keep your eyes peeled for local deals on materials and decide how to make solar panels based on what deals are available. For small solar panel projects, you might want to check out architectural salvagers for good quality glass. It is sometimes more practical to design a panel after you know the dimensions of your used glass. Plexi-glass is an option worth considering, but you will lose some efficiency over the years as it gets scratched and dull from weathering. On the flip side, plexi-glass makes more sense if you are placing the panels in a location where glass is at risk of breakage.
Regardless of which transparent covering you choose, they have to be weather tight or they may fog up. Condensed water vapor inside your solar panel will greatly reduce its efficiency and it could potentially corrode connectors and other hardware. Flexible sealing compounds are essential.
Photo Credit: GreenForAll.org
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