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.

In the course of these posts the information and explanations will be kept as non-technical as possible. My experiences include beginner hobby electronics projects which at least provides a good mathematical background and practical electronic soldering experience. Add basic woodworking and metal working/machining to that and I’m confident building my first solar electric panel will be a learning experience and hopefully of benefit for a few Rantsville readers as well..

OK let’s start with a couple definitions as they will be used throughout this series:

Solar Cell: As used within these posts refers to a photo-voltaic cell which is capable of generating approximately .5 Volt when exposed to bright light. The surface area generally determines the amount of current (amps) the cell generates in bright light.

Solar Panel: A number of solar cells linked together so as to increase the voltage and wattage output. For example if you link 2 cells in series, each producing .5 Volt at 3.5 Amps the resulting output is 1 Volt at 3.5 Amps.

That’s the down and dirty basics. The intention for the first solar panel project is an experiment to help determine the number of panels will be needed to maintain sufficient charge in a bank of batteries in order to operate a power inverter for the appliances we want to use without relying on an electric company. Individuality will dictate what those requirements are, thus I will not even attempt to define appliances you deem necessary that we may not. To begin with all I need is a test subject.

Over the summer much spare time was devoted to converting the powder coated steel framework of a Harbor Freight tarp covered storage structure into serviceable winter storage for my ’95 Goldwing. Price was right and the work exhausting but it’s a sturdy structure with both mine and my brother’s bikes inside. An extension cord can be strung through the back yard for lighting but I prefer not to do that to prevent the cord from falling victim to our snow blower. Over the winter light will be needed when accessing the shed for whatever work we need to do, plus a couple of motion sensor flood lights to keep honest people honest.

The absence of snow blower fodder while still having lights, minimal security and (not necessarily scientific) data collection easily justifies this solar panel venture. Wednesday when my check gets banked I’ll buy 36 solar cells from an eBay seller. Properly configured they will provide 18 Volts at 60+ Watts in bright conditions. I’m curious to know if that will be sufficient for the shed.

Part 2 to follow.