Build Your Own Solar Panel by Hurley
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Build Your Own Solar Panel by Hurley

Build Your Own Solar Panel Generate Electricity from the Sun by Phillip Hurley | PDF Free Download.

Build Your Own Solar Panel Contents

Introduction Solar cells

  • Solar cell basics
  • Amorphous cells 
  • Flexible solar cells
  • Crystalline solar cells
  • Monocrystalline and polycrystalline cells 
  • New cells vs. old-style cells 
  • Solar cell output
  • Watt rating of solar cells 
  • Testing solar cells 
  • Match solar cell output 
  • Tools for testing solar cells 
  • Using a calibrated cell

Solar Panels 

  • Solar panel output for different applications
  • Solar panel ratings
  • Designer watts 
  • Finding and choosing cells for solar panels
  • Tab and bus ribbon
  • Panel frames 
  • Thermal resistance
  • Moisture resistance 
  • UV resistance 
  • Glass in solar panels 
  • Plexiglas in solar panels
  • Solar panel backing and sides
  • The benefits of long screws 
  • Planning the panel wiring – series and parallel connections 
  • Voltage and distance to the battery 
  • Panel arrays and connections
  • Panel size and shape

Connecting solar cells

  • Choose and inspect the cells carefully 
  • Preparing the tab ribbon 
  • Flux 
  • Soldering
  • Soldering tips 
  • Soldering technique 
  • Types of solder

Building a solar panel

  • Materials and tools 
  • Figuring panel output 
  • Calculate the number of cells you will need 
  • Plan the panel layout 
  • Over-all panel length 
  • Over-all panel width
  • Bar stock length 
  • Cut the tab ribbon
  • Prepare the tab ribbon
  • Tinning 
  • Crimp the tab ribbon
  • Attach the tab ribbon to the cells 
  • Pre-tabbed cells
  • Make a layout template
  • Solder the cells together 
  • Prepare the panel structure 
  • Attach the screen 
  • Place the cells on the panel 
  • Attach the tab ribbons to the bus ribbons 
  • Insulate the bus connectors 
  • Junction box
  • Test the panel 
  • Seal the panel

A small solar panel array project

  • Solar II project specifications 
  • Panel layout and dimensions 

Panel construction

  • Panel backing 
  • Cutting the Plexiglas
  • Drilling the Plexiglas
  • blemished solar cells 
  • Repairing solar cells 
  • Creating cell fingers
  • Using broken solar cells

Making tab and bus ribbon

  • Tinning the cut foil
  • Other options for connecting cells


  • De-aerate the silicone
  • Cutting the silicone 

Solar electric system

  • Charge controllers 
  • Cables and connectors 
  • Batteries
  • Mounting panels 
  • Solar panel location 
  • Orientation
  • Panel maintenance 

Introduction to Build Your Own Solar Panel PDF

Converting solar energy to electricity via photovoltaic cells is one of the most exciting and practical scientific discoveries of the last several hundred years.

The use of solar power is far less damaging to the environment than burning fossil fuels to generate power. In comparison to other renewable energy resources such as hydropower, wind, and geothermal, solar has unmatched portability and thus flexibility.

The sun shines everywhere. These characteristics make solar power a key energy source as we move away from our fossil fuel dependency, and toward more sustainable and clean ways to meet our energy needs. The sun is a powerful energy resource.

Although very little of the billions of megawatts per second generated by the sun reaches our tiny Earth, there is more than enough to be unlimited in the potential for terrestrial power production.

The sunlight that powers solar cells travels through space at 186,282 miles per hour to reach the earth 8.4 minutes after leaving the surface of the sun. About 1,368 W/M2 is released at the top of the earth’s atmosphere.

Although the solar energy that reaches the Earth’s surface is reduced due to water vapor, ozone layer absorption and scattering by air molecules, there is still plenty of power for us to collect.

Harvesting photons for use in homes, factories, offices, vehicles and personal electronics has become practical, and economical, and will continue to increase in its importance in the energy supply equation.

In my opinion, the most exciting aspect of photovoltaic power generation is that it creates opportunities for the individual power consumer to be involved in the production of power. Even if it is only in a small way, you can have some control over where your energy comes from.

Almost anyone can set up a solar panel and use the power – independent of the grid and other “powers that be.” Batteries and supercapacitors for the electronic devices that we use on a daily basis can be recharged by this natural and renewable energy resource.

Doing so cuts down on pollution and makes life better for everyone. Practically every aspect of our lives will be touched in a positive way by the increasing use of solar electric power.

How to Use Build Your Own Solar Panel eBook


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