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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Used solar panels are a little bit like used cars with one very big difference.  The rate of depreciation is a big unknown with solar panels whereas depreciation is the major consideration with used cars.  Some of the earliest solar panels still function with a measurable but small drop in efficiency. If you have an unlimited area for your panels, efficiency is not a factor.  The measurement that you need to compare is dollars per watt.

If you are shopping in person for a used car, you will most certainly check to see if it runs.  The same is true for solar cells and it is pretty simple.  You bring a meter with you.  If the panels put out some volts and amps when in full sun, you are good to go.  Educate yourself about your meter and the expected currents from solar panels beforehand.  Frying an Amp Meter will surely ruin your day of solar panel shopping.  If there is no electricity generated, you should probably walk away.  You cannot predict how much time and effort it would take to repair them or if it is even possible.  An exception to this is burned-out bypass diodes.  If you can identify this problem as the reason for a solar panel malfunction you may be able to pick up some bargains from people who think that the panels are irreparable.  It is a common problem and it is not expensive to fix. Condensation under the glass is something that you want to avoid.

Panels do not degrade in storage.  Some types of used solar panels may have a plastic substrate that has turned brown after years of exposure to sunlight.  While this makes them look less attractive to buyers, it is not a reason to walk away.  If they generate watts when you test them in the sun, you should still include them in your comparison shopping.  Remember to compare dollars per watt generated.

If you test a panel and you are surprised by how much electricity you get, be aware that the nominal rating is lower than actual output in full sun.

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