The instructions not originally included with the solar cells only explained how to solder the included pre-tinned flat copper wire to the proper places. In other words nothing that wasn’t already known. Since learning little known secrets of solar panel building was what I had in mind, it was disappointing.

According to the seller each cell measures 3.25” X 6”. The truth is each is just over 3” and pretty much dead on 6” wide. Configuration for this panel will be with the cells in three 6” wide rows allowing 1/8” between each row. Each 6” wide row will contain 12 cells. Each cell is calculated at 3.125”. Actual outside dimensions for mounting the cells comes out to 37.5” X 18.25”. Although other configurations would work equally well, the three row arrangement made the most sense because it will require fewer pieces of flat wire and fewer solder connections.

Having decided upon the arrangement of cells, additional decisions regarding materials and assembly methods come into play. First was what to mount the cells onto and by what means. Second was which frame material to go with. Third was a choice between clear Plexiglas (acrylic) and clear polycarbonate at greater cost and greater durability.

Tough decisions those, but in consideration of this experiment, they pretty much fell into place: Initially I was going to mount the cells to primed and painted oriented strand board (OSB) but preparation and painting time plus the possibility of more problems keeping the cells secured in place brought me to some surplus 1/4” thick white plastic material available for $2/lb at a local discount hardware store.

Deciding on suitable edge frame material for the panel came next. For the sake of durability, fewest steps to finished product and little if any needed maintenance I chose aluminum channel designed to fit over the edge of ½” plywood. Compared to cutting, routing, priming and painting wood to make a suitable frame, the aluminum seemed the way to go.

Plexiglas (acrylic) was easy enough to decide upon simply as a matter of keeping experiment costs low while providing long service. Plus if a problem with acrylic crops up there will be no difficulty replacing it with clear polycarbonate.

My DIY Solar Panel Experiment is officially under way. There are eBay sellers anxiously awaiting feedback, and I’m hoping they will get my highest ratings.

Within the next day or two the adventures of soldering to solar cells will be revealed. There is a learning curve involved plus the cells are incredibly delicate. Stay tuned.