DIY Homemade Solar Panels
Building a solar panel can be a fun and rewarding project and can be accomplished at home with a little bit of work.Check out this video for steps and a demonstration on how to build your own homemade DIY solar panel and read on for further details, specifications and information.
It’s best to gather your panel’s materials before starting any work. Until you’re ready to work beyond building the frame and placing the glass into the frame, keep your solar cells in their original packaging to reduce any oxidation and aging that can happen when they’re exposed to the natural environment.
DIY Solar Panel Shopping List
- 11 feet of 1.5 inch aluminum angle iron at .125 inches thick.
- 16 nuts and bolts (14 for corner and L brackets and two for the terminal block.
- Clear Silicone Caulking
- 1/8 – 1/4 inch Tempered Glass
- 36+ Solar Cells
- 36+ feet Tabbing Wire
- 3 feet Bus Wire
- Solder
- Flux
- Two Terminal Terminal Block
- 16 or 14 AWG Wire (Two Colors)
- 16-14 AWG #8 Stud Feet
- 1 Diode
- Heat Shrink
- Encapsulant
DIY Solar Panel Specifications
Your panel’s dimensions will vary 100% on the size of cells you get and how many you want to incorporate into your panel. My project worked with cells that were 3 inches by 6 inches. Here are the dimensions for such sized panel at 36 cells per panel.
FRAME
Building the frame, my panels came out to 27.5 inches by 32.25 inches. With miter cut edges the ends of the frame pieces will have a shorter and longer size to account for the 45 degree angle cut at of the end. These lengths and dimensions are for the longer part of the ends.
GLASS
The glass piece to go with this panel size is 26.5 inches by 31.5 inches. I got clear 1/4 inch thick tempered glass. You should get tempered glass. Regular glass will break if a baseball hits it or if there’s a sudden change in temperatures, like with cool water on a hot panel. Most commercial panels would use much thinner glass but the 1/4 inch will stand up to 100 mph winds so it’s sturdier, stronger and will last longer.
ELECTRONICS
The cells are rated at just under 4 amps around .5 volts. When connected in series the entire panel will output about 18 volts and just under 4 amps. The diode needs to be rated at high enough amps (over 4 or even 5) and enough volts for the entire panel (more than 18 or better over 20). In the video I use a R-Schottky specified at 5 amps and 60 volts.
Choosing Your Own Panel Specifications
FRAME
If you want to create your own panel with altering specifications from this panel here what you will need to note. When the panel is finished you should ideally have a little space from where the cells are to the edge of the frame when looking at the face. This is because the frames slightly raised edge will create a bit of a shadow. Moving the cells inward and having some open glass around the cells will remove this issue. Also, when upside down, the glass pane needs to sit on enough of the angle iron edge to stay put, allow enough contact for the L bracket to hold the glass into place and have a resting surface but not extend all the way to the edge. There needs to be a bit of space between the frame edge and glass to fit in the corner brackets and screws.
CELLS
Just as with solar panels and batteries, connecting the cells in either parallel or series will raise or maintain the voltage. Since cells come in lower voltages, you’ll probably want to connect other types of cells in series as well: positive to negative to positive to negative. This will make the cells’ voltage additive. If you make a panel that is more than 18-20 volts, you’ll need to make sure to use an MPPT charge controller to not waste the higher incoming voltage. Check out this article to learn more about charge controllers and how they deal with panel voltages.
ELECTRONICS
Changing the voltages or amps in the panel specs may also require a different diode and/or wire guage. Make sure to get a diode that has a higher rating of volts and amps than what your custom panel will output. Also make sure to adjust the wire guage to accomodate any alterations in amperage. To determine if you need a different gauge of wire, check out the ampacity chart in this post about batteries and cabling in solar energy set ups.
What’s The Cost Difference?
The cost of solar panels have come way down within the last decade. It used to cost upwards of $5/Watt. But nowadays you can find and should shoot for $1/Watt. Building this panel was not worth it if you only take into account the dollars per Watt and time spent doing so, which are both incredibly viable things to weigh when preparing for your solar set up.
This panel’s specifications, rated on its 36 cells, would be labeled at about 68 Watts. However, you can never rely on getting the highest rating of a panel because panels aren’t usually at their maximum angle for more than an hour, if even that long. I had strung four cells together prior to building the panel to get an estimate of the cell’s amp output and instead of getting 3.8A or close to what the retailer claimed, I only got 2.0A or slightly higher. That makes the panel’s Watt output to be from around 35W up to 65W. The total cost of this project was over a hundred dollars. That means I’m paying about $2-$3/W…not cost effective.
On top of that inefficient cost, it took me hours and hours to make and I have no warranty. I can’t call anyone to complain or ask for service or support except myself.
However, this was not a surprise to me after the whole project. I knew it wasn’t the best way to get a solar panel but I really wanted to make one and I love that I did and I love my panel that I put a lot of time and research and even enjoyment into making. It’s definitely empowering to not just be able to say I built and know how to build a solar panel, but to have done it and ended with something that creates power! How cool is that! Pretty cool in my mind. So best of luck building your panels and learning while empowering yourself and broadening your mind. And if you choose not to for many good, solid reasons, good for you for keeping it simple!
You may be interested in this series of videos on solar basics:
As well as their corresponding articles and information:
Solar Panels and Charge Controllers
Inverters vs Converters and AC/DC Power
Batteries, Connections, Lithium Ion vs Lead Acid
Determining How Many Solar Panels and Batteries You Need
OK, I wanted to leave a comment on the flooring renovation, but could figure out how to get it so here is the suggestion. When do those cuts around the doors you take a scrap piece of flooring and lay it down flat near the cut. Then taking your multi-touch putting it on top of the scrap flooring and back-cut the trim, jamb and etc. This will cut a space that the flooring slides in, then the cuts on the flooring do not have to be as precise and it will go much faster. Sorry this is to late to help you but it may help others
That is a really great idea, thanks for your insight!
Hi, I purchased cells like this, built them into a frame just like your video shows and was getting 20 volts . Over a period of about three weeks I found the output drop down to about 9 volts which was useless. I put it down to the fact that the cells had not been sealed. Are you still getting 18 volts from your panel. I was interested to see how you mounted and enclosed the back of your panel but could not find the second video?
Cheers
Hi Colin, the second part was just released. Here is the link: https://youtu.be/YckHQS3TV84
Good job on construction and instruction, you gave a good general step by step description. As you stated making a panel is no longer cost effective, but its a good DIY for someone with free time. As long as you have the will to learn, you can do, or build anything, as you have shown in your many videos. Stay well
I’ve been really enjoying your Youtube channel, as well as your blog! Is there a public e-mail address you may be reached at?
Keep up the great content! 🙂
Hi Nikolai, you can address questions in the related blogs or in the RV living forum. Happy trails! 😀
Hey pippi been watching your videos last weeks. Have been waiting for your new videos very interesting stuff always fun to do DIY Projects. I am looking to find a RV myself to basically follow in your foot steps. Was wondering if I could pick your brain on few topics. Like what made u choose an RV instead of a 5th wheel or travel trailor? how do you feel your solar system is doin in terms of efficiency. Plus other questions reguarding RV living.
If I had the choice again, I’d probably want to get a fifth wheeler so I don’t have to maintain an engine plus I’d love the extra space. I’m still installing my roof top solar collector module. Stay tuned for those videos 🙂
Hi, thanks for doing this video, its very informative. I am looking for a good info on solar power, I am planning to build a solar power water pump here in the Philippines…I am glad I found this…
thanks,
Connell
Glad to hear that. Good luck with your water pump! 😀
Hi Pippi, Stumbled on your youtube videos yesterday. Some really good content. If you’re undecided on batteries, you should consider going with a diy li-ion tesla style battery pack. Tons of great info for them on youtube. There’s also a facebook usergroup and a forum setup. https://www.facebook.com/groups/diypowerwalls/
http://diypowerwalls.com/
Interesting, thanks for sharing! 😀
hi,
i am from MOROCCO, it s simplly greate the way you explane it.
my english is not perfect but so excuse me if i make some mistakes.
i would like to make a 200 w pannel should i use the same components ?
thanks again for your videos.
You will have to see what cells specs are offered. Most likely your dimensions will not match mine. This will depend on your cells and their specifications. Lower Watt cells will require more and higher Watt cells may be larger. So the glass and framing will be different and you will likely need more encapsulant material. Best of luck with your panel! 😀
somebody mentioned a flux capacitor, where does this go and how does it go on the panel ?
The flux capacitor goes right next to the inertial dampening field. It requires a left handed monkey wrench for proper installation.
I don’t think it was a waste of time. I have run into people offering me free solar cells, and if I added them all up, I could have made a cell for almost nothing. Your thorough instructions would have compelled me to build one. I may have access to a piece that came off of a roof for a house. I learned a lot in that video. I would try and buy a Weller, or temperture controlled soldering Iron one. The one you have is over kill. When sing flux cold solder, you do not need to add Flux. Doing so will make it spatter and make a mess. I had an electronics repair shp for 10 years. Instead of holding parts down with the Iron, it is better to use a sharp awl, like a small Ice Block cutter. This allows the matrix to cool properly, and you won’t have such bulky solders on your projects. I learned so much from that video. Thanks, I’ve just joined you site and expect tovisit often. Do you have a way of posting pictures, here, or in the forum? 🙂
Thanks so much Zathros. If you want to add pics, the pics must have a url. 🙂
Thanks Pippi, you are Happening! 🙂
Pippi, just wanted to say you absolutely ROCK! Discovered your YouTube channel several months ago with your axle greasing tutorial. Been following you ever since. Mad respect for you and your fuzzy room-mate. I’m also a full-timer with my bflf (best four legged friend). If you ever want to get away from all that beautiful weather, feel free to swing by the Mohave desert and help me rewire my fifth wheel brake lights!
Keep up the great blogs/vids/projects.
Regards,
Charlie
Thanks Charlie, I’m happy to have you as part of the community. Thanks for tuning in and happy trails! 😀
Hey There Pippi!
How’s everything going? Been watching the videos and taking a mechanic’s class to move me forward. What I’m really writing about is the fact that I was talking about the RV life in class and this chick asked where would you park at? This guy mentioned Coney Island parking lots. Her point was foregoing paying property taxes just to live in an RV was ludicrous. We’ve both heard the arguments already. Many of them ran through my mind as I sat there quietly letting them think they made me feel stupid for such an idea. She missed my whole point. There’s so much money to be saved living in an RV.
Basically they feel as if you’re substandard for living such a life. Yet they forget that there are millionaires living the RV life. For some odd reasons they just can’t comprehend the concept let alone understand that some RV’s cost more than their house! Amazing! Another point that I was making is that a traveling mechanic can make a decent living dealing with RV’s. Have a nice trip!
Shannon
That’s awesome you’re taking a mechanic’s class. That’s something I’d like to do as well. Did you know they have RV technician classes too!??! You can’t expect everyone to understand living in an RV and you certainly don’t have to listen to what they have to say negatively about it. I’ve found it’s the cheapest way to live a pretty normal and good life. Unless someone has specifically carved out the details of their life to their own liking and not by following the social standard, you can’t expect them to understand when you do it. Happy trails Shannon and best of luck with your classes!
Oh yeah… And by the way…You is NOT! Building a solar panel! Wow! You go girl!
Thank you so much. Your videos are really informative. Live long
Thank you! 😀
Love it . May be easier for me than it was for you volt output will very depending on your soldier ability keep it coming I’m a fan (stalker) ha! Kidding
Thanks for tuning in.
Thank you so much , your description very useful…..
Glad to hear, you’re welcome. Thanks for tuning in 🙂
Nice videos!! I am going to look for that your shopping list as I think it would be a great project to work on with my kids. Again – Great job!!
Hi,
I was wondering, do I have to use special cable to wire a pv panel?
Can’t i use regular thick electricity cable?
Regards
David
The wiring I used is regular wires from Fry’s and Home Depot. Good luck!
Pippi is correct, the only way to get the full capacity of the panels would be to mount on a motorized platform that would basically follow the sun throughout the day. The cost of such a platform would not be cost effective for an RV. Great work Pippi!
Please, can you help me out with the solar panels and some things that i may need.
Great video! I’m gathering materials and one thing I wasn’t expecting was the high cost of the tempered glass. At that size, at 1/4 thick, I’m getting a price of almost $100 for the glass alone from online places that cut to size. That kind of blows my budget. Do you think I could use plywood, or plexiglass instead? I’ve seen that done in some other tutorials.
Hi, great video. I wonder if there’s an alternative to the tempered glass, which I’m finding is quite expensive to get cut to size at 1/4″ thick. I get a price of almost $100 for the glass alone. Can I use plywood or plexiglass instead?
thanks
Yes you can however, plexiglass can turn yellow over time and limit the amount of PV rays getting into your solar cells.
Hi pippi! This is an amazing video ,it has inspired me in making solar panel as the one who live in Africa ,a continent which is highly illuminated by solar. but i still have confusion about some materials,
I would recognize you again ,if you can be my mentor so that i can build it at home.
Will you help me? If is yes,i will ask you some problems encountered during the process. Thanks too.
I like your video on solar maybe you can help me with this.i want to get 400wt for my solar but I’m having trouble with trying to figuring it out.how many would I need?
Dear Pippi,
We need more girls like you on this planet! You are such an inspiration (and you are charming too- if I may say that). I am a M.S. in Electronic Engineering and did test instrument making from scratch for years, just like you did with the panel. Electronics was also my hobby for the longest time, I built my first stereo system myself (back in East Germany). Same conclusion to “was it worth it”?- Yes and No, I learned a lot and had fun but I could have bought one cheaper (after the the re-unification of East & West Germany).
I am proud of you and hope you will continue like that. Good Luck to you!
Thank you!
I wanted to say best ever explanation .i understood and I am not the brightest ?. Thank you many loves your way… God bless u
Thank you!
Hi, I was scrolling down my YouTube app and it appeared your video of how to make a solar panel from scratch and I’m so thankful because this video is exactly what I was looking for. I don’t want to pay for a ready-to-install solar panel, I want to learn in the process, all I can say is “thank you” because the whole video and blog post offer all the information that you need.
I live in Venezuela in South America, we are having a bad time specially with the electricity, we are experiencing blackouts for around 1-5 days, so the people is buying power generators, they work with gas and I’m asthmatic patient. I’m looking for a clean solution and solar energy is a really good idea but I don’t want to pay extra money for something that could be fun.
Once again, thank you so much for publishing these videos.
Continue the good work you are an inspiration
How many solar cell need to 100watts, 12v
panel?
Pippi, not sure how you hold the cells to the panel. Is it done with the silicone or the encapsulate?
Where do I buy the tempered glass?