Making solar panels at home is easy with the right materials and instructions. You can make a solar panel for as little as $ 200. The materials you need are: solar panels, plywood or plastic board, UV protector for plywood, Flex-glass, tin wire in two different thicknesses, silicone, solder, soldering iron and or gun, rosin flux pen, nuts, bolts, and to use wood or metal as a frame, and a junction box. You’ll also want a voltmeter to test your panel. (You can borrow this from an electrician.)
1. Create a template. A template ensures that each cell is evenly spaced. You can buy 5×5 inch cells for this project. Draw a template to make sure that each cell in each row about 1/4 inch apart. Allow a few inches to the outer edges of the frame of the panel.
2. Cut the plastic board or plywood to the size of the panel you want to build. You will want to figure out the size of the board or plywood cut. If you need 100 watts of power you will make a panel with 50 cells. You may not need that much. If you use plywood, you will want to protect it with a layer of UV-Guard.
3. Cut the wire tabbing Cut the wire the same length of two cells plus 1/4 inch so if you use the 5×5 inch cells, you’d length 10 1/4 inch long cut. Cut two for each cell. You will find half of the solder wire to the negative side of one cell and the other half of the wire to the positive side of the next cell. If you have not coated wire to solder the wires or put on the tabs of each cell.
4. Use the pen flux and solder gun. Each cell has two tabs on each side. Enter the flux pen along the tab of a cell (blue side or negative side) where you are going to fix the tabbing wire. Solder the wire to the cell. Solder a second wire along the second tab. Do this with all cells.
5. Confirm all the cells in rows. Now turn the cells and excess solder the wire to the positive side of the other cells that five rows of 10 cells (if you are 50 mobile panels). The negative side of the cell # 1 attaches to the positive side of the cell # 2 to make sure that each cell quarter inches apart in each row.
6. Attach rows with heavy thread: You are going to use the thicker wire to all the cells adhere to each other at the ends. You will be
to connect in a series, which means negative to positive and negative to positive through the panel connecting each row. 7. Testing with the voltmeter. Connect the voltmeter to the wires on the cells to make sure it works properly
8. Use the silicone to the rows of cells onto the panel.
9. Turn wires through the junction box: There are two pieces of wire remnant of attaching the wires in a series: a positive and a negative that you solder a positive and negative electrical wire. Pull have attached through the back of the panel and in the terminal box to the rear of the panel with silicone. You can check out the link below to get the guide for full details.
10. Framing. You can use a wooden ledge as a frame for the plywood or metal c frame for the frame of the plastic plate. Use of silicone to secure the support, and then use nuts and bolts in order to keep it tight. Use different bolts and nuts to the c metal frame attached to the panel.
Source: http://ezinearticles.com/?Making-Solar-Panels-at-Home—Build-a-Solar-Panel-For-About-$200&id=2593416 by Aleta Grahm