Create Solar Panels

Creating your own solar panel is easier than you might think.

Creating your own efficient, low-maintenance and inexpensive solar panels is no longer a job reserved for people with an engineering degree. Most items that you will need for your creation can be found at a hardware store and online. Solar panels will help you reduce or even eliminate your monthly electric bill. Solar panels can also be made to power or recharge portable devices such as laptop computers and DVD players. RVs, boats and backcountry retreats can especially benefit from the installation of solar panels.

Instructions

Solar Array Assembly

1. Arrange 96 solar cells face down on a clean, smooth, level workbench; align all terminals on the back side in the same direction, creating four square or rectangular arrays.

2. Touch the heated soldering iron to the soldering tabs on the solar cells, leaving a small amount of solder on each tab. Try not to touch solder wire directly onto the soldering iron; doing so will make a mess.

3. Solder flat wire from the positive tabs to the negative tabs on adjacent cells. Repeat this step, forming four separate 24-cell arrays. This is called a series wiring scheme. Touch the soldering iron to the flat wire, not the solder on the terminal. The solder on the terminal will automatically "soak" into the flat wire.

4. Test the power output of each array with a multimeter. The total output should be at or above 12 volts in direct sunlight.

5. Remove ¼-inch of insulation from the appropriate length of number 12 red insulated wire, using the wire strippers, and solder to the positive terminal on any cell to connect the cells to the positive terminal. Repeat for all four arrays.

6. Remove ¼-inch of insulation from the appropriate length of number 12 black insulated wire, using the wire strippers, and solder to the negative terminal on any cell adjacent to the red wire for appearance. Repeat for all four arrays.

7. Clean the solder connections, using isopropyl alcohol and a detail brush. Remove the brown corrosive solder flux rosin. Not cleaning the solder connections will result in damage to the cells and wiring.

Create Panel Box

8. Cut three of the 1-by-2-inch wood studs into 46-inch pieces. You should have six pieces the same length.

9. Drill four 3/8-inch holes in three of the 46-inch studs. These will be the center beams in the panel box. The holes are for ventilation and wiring.

10. Arrange two 8-foot studs and two of the 46-inch studs in a rectangle. You will end up with a rectangular shadow box. Create four equal-size compartments by placing the three pre-drilled pieces every 21 1/2 inches inside the box, parallel to the two end pieces. Each piece should be set on the 1-inch side, creating a 2-inch-deep panel box.

11. Drill pilot holes, using the 1/8-inch drill bit. Drill a 2-inch side of each 8-foot piece into a 4-foot piece, two holes per end, for a total of 20, including center pieces.

12. Fasten all studs to each other, using wood glue and 1½ -inch wood screws. Do not completely tighten until all screws have been started. Frame dimensions will be 48 inches (4 feet) by 96 inches (8 feet).

13. Apply a small bead of wood glue around the edge of the box frame that you will be mounting the plywood sheet on.

14. Place the 4-feet-by-8-feet plywood sheet on the frame, making sure all edges are flush. Secure to the frame with 1-inch wood screws evenly spaced around the perimeter of the plywood, ½ inch from the outside edge. This step completes the panel box.

15. Remove excess wood glue with damp rag.

16. Drill two 3/8-inch holes into the plywood for wiring purposes. The holes should be located near what will be the bottom of the panel.

17.Seal the panel box with a urethane wood sealant such as polyurethane. Feel free to apply multiple coats, especially if you live in a wet climate. Let the sealant dry at least 24 hours or as directed on can.

18. Align the acrylic sheet over the panel box. Pilot drill 1/8-inch holes around the perimeter of the sheet. Remove the sheet and enlarge all holes in it, using a 3/16-inch drill bit. Do not enlarge the pilot holes on the panel box.

Final Assembly

19. Duct tape the solar cells in each array together on the back side of the array to prevent damage to solder connects while handling. Apply a generous amount of silicon sealant to the backs of the arrays to hold them in place inside of the panel box.

20. Place arrays in panel box.

21. Guide all insulated wires to the two 3/8-inch exit holes at the bottom of the panel box. All red wires go through one hole, and all black wires through the other. Seal the exit holes with silicon sealant.

22. Apply a small bead of silicon sealant around the outer edge of the top of the panel box. The sealant will help bond the acrylic sheet to the panel box.

23. Place the acrylic sheet back into position, making sure that the holes are lined up properly with the pilot holes on the panel box.

24. Secure the acrylic sheet in place, using ½-inch buttonhead wood screws. Do not over-tighten; you will crack the acrylic if you over-tighten the screws.

25. Apply a small bead of silicon sealant around the outside of the acrylic-wood contact area. Smooth out, using your finger or a putty knife, making sure there are no gaps or void in the sealant.

Not stop draining

Tuesday, June 18, 2013