How to Make Your Own Solar Panels from Scrap Materials

Making your own solar panels from scrap materials can be a fun and rewarding DIY project. With some simple materials and basic skills, you can build a small solar panel to power small electronics or add to your off-grid power system. Here is a step-by-step guide on how to make your own solar panels from scrap.

Gather the Necessary Materials

To build a solar panel you will need the following materials:

• Scrap solar cells - The most important component. You can salvage these from old solar garden lights, battery chargers, RV panels etc. Try to get cells of similar size and power output.

• Tabbing wire - This thin copper wire is used to interconnect the solar cells. You can salvage this from old panels or purchase it.

• Bus wire - Thicker gauge copper wire used to connect rows of solar cells. Scavenge from electrical wiring.

• Soldering iron and solder - For connecting all the components together.

• Transparent glass/plastic sheet - To cover the top of the solar cells. Acrylic sheets or old glass windows work well.

• Weatherproof backing - A non-conductive material like plywood or plastic to mount the cells on. Avoid using conductive metal.

• Silicone sealant - To weatherproof the panel when assembled. Clear 100% silicone caulk works best.

• Junction box - Houses the connections and terminals. Can be salvaged from an old electric device.

• MC4 Connectors - To connect the panel to controllers/batteries. You can buy these online or sometimes salvage from old solar panels.

Prepare the Solar Cells

The first step is preparing the individual solar cells for assembly.

• Carefully remove the solar cells from their old housings using pliers, wire cutters, and screwdrivers. Try to keep the tabbing wires attached.

• Inspect each cell for any cracks or damage. Set aside any faulty cells.

• Clean each cell thoroughly with isopropyl alcohol to remove any dirt, adhesive etc. This improves their power output.

• Use a multimeter to test the voltage output of each cell in sunlight. Arrange cells with similar voltages together.

• Solder longer lengths of tabbing wire to each cell contact point to make connections easier. Apply heat quickly to avoid damaging the cells.

Assemble the Solar Panel Frame

Now we need to assemble our backing frame:

• Measure your solar cells and cut a non-conductive backing board a little larger to allow a border. Avoid using conductive metal.

• Drill small holes along the edges to mount the junction box, connectors, and to cable tie the wires.

• Adhere a layer of foam weatherstrip tape around the edges to seal against the glass/acrylic cover.

• Mount the junction box to the back using screws or an adhesive. Leave room for connectors.

Connect the Solar Cells

With the frame complete, we can now wire up the solar cells:

• Arrange your matched solar cells in rows on the backing board aligned evenly.

• Solder the tabbing wires together to connect the cells in series. Make sure solder points firmly connect but avoid creating bridges between cells.

• Use bus wire to connect each row together in parallel. Run wire through the drilled holes.

• Connect the wire from the last cell to the junction box terminals. Fuse the positive wire for safety.

• Secure all wiring neatly to the back of the panel using adhesive or cable ties so it does not touch the cells.

Seal and Weatherproof the Panel

To protect your panel you need to seal and weatherproof it:

• Cut your transparent acrylic/glass cover to size allowing a small overlap on all edges.

• Clean the glass cover fully using isopropyl alcohol and clean cotton cloths.

• Apply a continuous bead of clear silicone caulk around the entire backside edge of the cover.

• Flip the cover over and gradually lower it onto the panel frame allowing it to spread evenly.

• Use clamps or heavy objects to weight the cover down as the silicone dries fully. This prevents leaks.

• Run a final bead of silicone around the outside edges for an extra seal when dry.

• Allow 24 hours for the silicone to fully cure before using the panel.

Add Wiring and Mounts

The final steps are to add cabling and mount your new solar panel:

• Drill a hole through the backing board and silicone seal for the cables to run through.

• Connect MC4 leads or waterproof cables with strain relief to the connectors.

• Use a pole mount, racking, or build a tilt frame to angle your panel towards the sun.

• Point your panel south (northern hemisphere) or north (southern hemisphere) to maximize sunlight exposure.

And that's it! With your custom DIY solar panel complete, you can start generating free electricity from the power of the sun. Always check voltages and use caution when wiring panels and connecting to batteries or charge controllers. Have fun harvesting renewable energy!