Build Solar Panels For Less Than $100

Yes, it really is possible to build solar panels for less than $100, and you don’t need expensive tools.  But let’s be clear that we are not talking here about creating a solar electric system that will be able to power your entire house or tie your electrical system into a local utility company’s grid.  That kind of project usually involves local building codes and extensive electrical knowledge.

What we are talking about is building one or more solar panels that you can use to generate enough electricity to power your computer or the lights in your garage workshop with free energy from the sun.  And you can do it using simple tools, materials that are readily available from your local hardware store, and a few pieces of solar equipment that can be easily found online.

DIY solar panel materials

Since solar panels have no moving parts, the materials used to build them are relatively simple.  You’ll need to build a wooden frame using either wood from your local lumberyard or your own scrap pile, along with screws to hold it together. (Aluminum frames cost a little more to build but will last longer.)  For the back of the box, it’s best to use UV resistant paint to protect it from prolonged exposure to the sun.  Plexiglas is the best material to use for the cover.  It lets in the sunlight, is light weight, inexpensive and easy to cut to size.  You‘ll also need solar cells, the wire to link them together and soldering flux for the connections.  For finishing, you’ll need silicone caulk to seal and weatherproof the box.

Homemade solar panel tools

You may have most of these tools already, but if you need to purchase them, most are not expensive.  To build the box, you’ll need a saw to cut the wood and Plexiglas, a screwdriver, drill, paintbrush and caulking gun to finish it.  A soldering gun and flux pen will be necessary for connecting the solar cells.  You’ll need a multimeter to test the strength of the electrical current.  And you should also wear shop goggles or other protective eyewear, glove and a respirator for health and safety purposes.

The most time-consuming task in the process will be wiring and soldering the individual solar cells together.  But the accuracy with which you perform this task will determine your solar panel’s electrical output.  You will need to monitor the strength of each cell by using the multimeter to verify its current when you are wiring the cells together.  Since using even one cell with sub par current will decrease the current in the entire series of cells, it’s important to take this quality control step.

 Green Do-It-Yourself Energy