The first DIY Solar Panel Experiment, (the one on the backyard shed) was assembled using silicone adhesive sealant. The panel was producing electricity to the moment it was disconnected from the charge controller and removed from service. A couple factors dictated the need to be dealt with quickly. First were ever expanding cracks from screw holes in the front panel. Second was an obvious warping problem with the rear panel which is where the solar cells are mounted causing about six cells to break up. Preventing further damage and hopefully salvaging most of the remaining intact cells became the order of the moment. Little did I suspect silicone adhesive sealant was one of the culprits.
The rear panel was fabricated from several acrylic pieces glued together using silicone adhesive sealant. For some reason, one glued edge pulled away and warped toward the fragile solar cells breaking six of them. Oops! Two lessons learned: 1-sometimes the bargain basement method isn’t a bargain. 2-silicone isn’t the right adhesive for the job. Future back panels will be one piece even though my original panel may have been just fine if bonded with a different adhesive sealant material. read more…
Phase two of the DIY solar panel project is a fresh start with a larger and much higher output panel design. With lessons taken from the first project and further research under the belt there is no question this and future panels built will be far superior to the first (hopefully rivaling commercially available units). So it’s time to get this show on the road.
After exploring different dimensions and layouts using inexpensive CAD software installed on one of our computers, a combination of online and local comparison shopping took place. Buying aluminum bar locally is more expensive than ordering online. That may be subject to change as I continue researching local suppliers. Clear acrylic (AKA plexiglass) 30” X 60” X .080” thick are available locally for about $22 each. Going with different dimensions would mean buying 48” X 96” sheets at about $90 and personally cutting the pieces to size. Time required, the risk of ruining at least half a $90 acrylic sheet versus getting two 30” X 60” pieces for under $50 made going with already cut pieces economical and logical. So acrylic it is for both the front and back panels. Aluminum sheet can be used for the back panel but higher cost and added work electrically insulating the aluminum makes the acrylic a more practical choice. read more…
