Note: this is part 2 of my, How to Build Solar Panels in 7 Easy Steps. You can find steps 1 through 3 here: How to Build a Solar Panel in 7 Easy Steps (part 1)

How to Build Solar Panels – Testing the Solar Cell Array

Now that all of the solar cell arrays have been put together, it is best to test the solar cells to ensure your connections were made properly. This is simple and easy. Place the solar cell array face up and in direct sunlight. Using a multi-meter, measure the DC Voltage across the (+) and (-) terminals. The voltage of each array should read 0.5 Volts times the number of solar cells per array. For example, if you have 4 arrays of 9 cells then each array should read 0.5 Volts x 9 cells = 4.5 Volts.

If you measure 0 Volts then one or more of your tab wires is not making proper contact. You will need to revisit the “Connecting the Solar Cells Together” step above and touch up your soldering.

How to Build Solar Panels – Gluing the Solar Cells to the Backing

Now you should have a few complete solar cell arrays that are ready to be attached to the backing. You will want to orient the arrays such that every other one is switched in polarity from the adjacent arrays. For example, start with the bottom of one array being the negative (-) terminal. The next array placed next to it should have the positive (+) terminal at the bottom. The next should have the negative again and so on.

Start by placing the solar cells with the back side up. Add a small amount of silicone glue to the center of each solar cell. Carefully turn the solar cell array right side up and position it carefully and properly onto the backing. Be careful not to smudge the glue all over and do not apply so much pressure that you break the cell.

How to Build Solar Panels – Wiring the Solar Arrays Together

Now that the individual strips or solar cell arrays are attached to the panel backing you can wire them together in series so that they all work together to provide a total of 63 Watts of power.

Wiring in series means that you want to wire them in a snaking pattern. Start with the negative end of the outermost strip and using the bus wire, connect this to the adjacent strip’s positive end which should be directly next to it. Then follow this second strip to the opposite end which is again the negative end and connect it to the positive end of the third strip.

Continue to connect all of the solar array strips in this fashion, connecting negative to positive and snaking the entire length of each solar array. When you are finished you should be left with two unconnected ends which are the positive (+) and negative (-) terminals of your solar panel.

Now you can solder two insulated wires directly to these terminals which will exit the solar panel and act as the main terminals hook ups for your solar panel.

How to Build Solar Panels – Covering the Solar Panel

You have now almost completed your first solar panel. At this point you will want to build a wooden border if you are using plywood. Or if you are using a plastic border then you should use metal framing. You can then cover the solar panel using a sheet of plexi-glass and secure it using silicone caulk.

You will also want to drill two small holes in the solar panel backing and run the terminal wires out. Be sure to use silicone caulk to seal all joints and bus wire holes of the solar panel housing and plexi-glass covering.

Congratulations, you have just built a fully functional 63 Watt solar panel for $100’s less than the cost of the same exact commercial model solar panel.

Now that you know how to easily build a single solar panel, you can build even more of them to increase the power generated by your solar power system. Every time, it will get easier and faster to build. You can also build them in different configurations to get even more power output for your solar power system.

I hope you have enjoyed this lesson on how to build solar panels and continue to build more just like it to help you save even more money. If you had any difficulties then do not worry. You can always use one of the guides that I recommend which will have video instructions that make the entire process much easier to follow and perfect.