Building a Solar Panel Part 1

wood panel 1024x768 Building a Solar Panel Part 1

I have started to build a solar panel to use for a class project here, and eventually in the Philippines. I searched the web and found that it’s possible to build a lower cost 60 watt PV panel, possible less than $200.00. One of my goals in building this panel is to learn more about this technology and to refine my skills. I also have a few of my middle school students that are eager to help and this will be a good learning experience for everyone involved.

I would also like to incorporate the solar panel into my large Mars Habitat project at the end of the school year. Maybe we will be able to generate enough power to run one of the fans. I’m not sure where all this will go, but I think it will be a fun project.

I already bought a piece of wood 3/8 inch thick, 2 feet by 4 feet plywood at the local store. This size wood is precut and easy to bring back to school. The only problem is that it’s a little warped. I’m not sure if this is critical or not. I plan to trim the perimeter with 1″ trim wood to add strength. Today I started to paint it and I’ll finish painting it tomorrow. So far, the cost of the wood, trim wood, paint and brush cost $38.00. Tomorrow I want to finish painting both sides and add the perimeter trim to strengthen the panel.

21 Responses to Building a Solar Panel Part 1
  1. Randy C
    April 27, 2009 | 7:55 pm

    Hi Kevin – I’ll be real interested to see how this turns out.

    Sorry I haven’t been available lately, and it’s not looking good any time soon. I’ll be in touch though.

    [Reply]

  2. Kevin
    April 28, 2009 | 5:00 am

    Randy,
    Hey, good to hear from you. We have a mini heat wave here in PA. It was 94 yesterday and low 90′s today so I only painted some of the panel as it was drying too fast. I’ve got most of the project completed in my mind, just gotta keep working on it everyday. Got all my tools in my classroom now so that should help.

    [Reply]

  3. Gerald
    April 28, 2009 | 9:12 pm

    Hi Kevin,

    Looking forward to the next installment! I’m very interested in solar energy and would certainly be interested in saving some money on a PV setup!

    Thanks for posting!

    Gerald

    [Reply]

  4. Kevin
    April 28, 2009 | 9:57 pm

    Gerald,

    My students finished painting the panel today. Thanks for visiting.

    [Reply]

  5. Randy C
    April 29, 2009 | 10:12 am

    Kevin – looks like a good idea for a business there in the Philippines, if you can keep the unit costs down ;-) Labor would be cheap, not sure about parts.

    Samal Island Solar Co.

    [Reply]

  6. Kevin
    April 29, 2009 | 3:55 pm

    Randy,
    Samal Island Solar Co.

    Yes, that does sound pretty good. I think the problem for the masses is that it will still be too expensive. For my project I hope to get a real clear idea of what would be the lowest cost to build the PV solar panels. For this project, the labor is free and the only cost is the parts.

    Another consideration is the other costs like an inverter and batteries. But you never know, maybe I can get them used or something. I plan to find out.

    Today, my students finished painting the panel and trim wood. I drilled the perimeter pilot holes and attached one piece of trim wood. Some of my students and bringing in spare wood tomorrow.

    [Reply]

  7. Randy C
    May 16, 2009 | 3:52 pm

    Hi Kevin – how did this project turn out? You ready to start priduction ;-)

    [Reply]

  8. Randy C
    May 16, 2009 | 3:52 pm

    Production, that is!

    [Reply]

  9. Kevin
    May 17, 2009 | 5:22 am

    Still working on it. Almost done. Post coming Monday.

    [Reply]

  10. Alex
    June 28, 2009 | 3:24 am

    Hello,

    I am interested to build a solar pannel in the hilippines too.
    WHere can I buy cheap pannel and converter? My plan is to run my regrigerator with solar power.

    Alex

    [Reply]

  11. Kevin
    June 28, 2009 | 7:40 am

    Hi Alex,

    Welcome. They sell solar panels in Manila and Cebu. I have not found any in Davao. You can search the web to find the prices there. I think you will need more than one to power you refrigerator. Where are you located in the Philippines?

    [Reply]

    Kevin Reply:

    Also, you may need more that one solar panel to run a large appliance.

    [Reply]

    Kevin Reply:

    Alex, I’ll keep looking for a solar energy business in Davao.

    [Reply]

  12. Alex
    June 28, 2009 | 9:07 am

    Well, I am living in Lipa-City / Batangas.
    Yes I think too, I will need more than one panel! The refrigerator I am using have 220V/90W
    Many times there is a brown out and all the ice is melting inside. So that would be a good thing, because sun is shining most of the time.
    Do you know a place in Manila, where to buy such kind of stuff for a good price?

    [Reply]

  13. Kevin
    June 29, 2009 | 10:21 am
  14. Jack Mascarinas
    October 7, 2009 | 1:59 pm

    I am interested in building this business too for the Philippines. I have some instructions how to do it with parts available in the United States.

    [Reply]

  15. alex salvador
    October 26, 2009 | 12:14 am

    i’m interested to build a solar panel for home use.

    [Reply]

  16. mary salome kelly
    November 30, 2009 | 6:55 am

    I am in San Fabian, Pangasinan, Philippines right now and will be here for a couple of months, I am very interested in learning about this so I can share it with very poor villages.

    [Reply]

  17. Kevin
    November 30, 2009 | 9:19 am

    Hi Mary,
    It take some time to build and the parts are not that cheap. The cost of the solar parts is still too high for the average Philipino to buy.

    [Reply]

  18. Ben
    May 21, 2010 | 9:14 pm

    Solar-powered house is very flexible because you can just start build come panels for your house first then if the performance is beyond average you might consider to expand it and make an extra solar panels. Now that’s the reason we should try to build one!

    [Reply]

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