When constructing a solar panel for outdoor use it is desirable for the cells to be housed in an air tight enclosure. That isn’t a problem using readily available materials. The problem is that even though it is air tight the enclosure has air containing moisture equivalent to the relative humidity the day it was sealed into the enclosure. As temperatures repeatedly vary there will be condensation cycles which will eventually cause electrical shorting thus shortening the useful life of the panel. A popular means of dealing with that is to encapsulate the cells with moisture proof materials. In this case the cells are secured in place making encapsulating pretty much out of the question. Dang!

Because the cells are already secured to the back panel, it appears the best option to add longevity is remove moisture from the internal air after the assembly is completed. Can that be accomplished? Let’s just say I have a plan. One thing for sure, the project (and costs) to this point aren’t going to end up sitting at the curb on trash day. Nope, the panel will be finished and used as intended until it no longer functions. In the meantime it will be good for comparison to future panel projects. Who knows, maybe it will serve as well and as long as the next panels constructed according to (supposedly) better methods. Wouldn’t that be a hoot?

So the project goes forward. Starting with the next post photos and detailed explanations of each step will be included. You will have enough information to be able to duplicate this project. That’s not saying you should do that since there are better ways of making solar panels but you will have the advantage of knowing the mistakes I made, techniques for working with solar cells to avoid the “oh shoots” (not exactly my words but trying to be polite) and numerous insights along the way. Following this experiment to it’s finale will get you well prepared to avoid my mistakes and economically build proper solar panels. Or you can go about the learning curve from scratch and consider the cost your tuition.

Video documentation of the next solar electric panel is the plan. Of course, that’s assuming a suitable digital video camera within the finances of an old guy on disability can be found. I believe in miracles, don’t you?

The solar cells arrived last week. Included with the cells was pre-tinned tab and bus wire, flux and solder. Not included was the “instruction manual” which the seller promised would be in the mail Monday morning. It hasn’t arrived yet but it is only Wednesday. Previous research and experience caused the temptation to just go ahead and get started anyway. I have resisted, just in case there may be little known methods, techniques and secrets within their information versus information gleaned from other sources. Somehow I’m expecting to learn very little more, but just in case, I wait.

Do it yourself projects usually start by mulling over what you intend to accomplish until the goal is pretty clearly cemented in the mind. General details, for that matter even intricate details are frequently worked through before anything gets put on paper, into a text document or a CAD drawing. In the mind’s eye the project is completed in seemingly no time. In actual hands on doing it, well the time factor expands exponentially or at least that’s how it feels. I hesitate to speculate how much additional exponential expansion will result from documenting with pictures (possibly videos) plus lots of instructive text and probably more. One thing for sure, it ain’t gonna be just making a solar panel and explaining what and how I did it.

I tell ya, some of the things I get myself into. OK, let’s not go there.