If you look at the cost of readymade solar panels you are likely to get a strong dose of sticker shock, so is it possible to make solar panel systems at home?    The clear answer is an unqualified YES.  You will find a huge amount of advice online to show you how to make a solar panel.  The main problem is trying to sort out the expert advice from the dangerous stuff.  

We have searched through all this information using our own expertise in solar panel construction, to give you all the basic advice and guidance needed. 

The first thing is that you will not need any particular skills or technical knowledge, which is really good news.  You can get all the necessary materials quite easily, or perhaps even find them from scrap.  It is quite possible to make your own solar panel for under 200 dollars and in a weekend.

And more good news – making solar panels is a simple and straightforward process.  Here are the basic steps.

As always, it pays to plan things properly before starting to make anything.  These are the main things to consider:

Location:  Solar panels are dependent on sunlight so should be sited to get as much sun as possible.  Avoid costly mobile units that constantly face the sun as it moves across the sky.  It is better and cheaper to build several fixed solar panels even if it is slightly less efficient.  Ensure that your solar panels will not be shaded by trees or tall buildings at any time of the day.  

Fitting:  You can mount your solar panels on your roof, on the ground, on a wall, on a garden shed – anywhere convenient and suitable.  Since they are a little delicate, it might be a good idea to keep any solar panel out of reach of children and animals!

Tools and Materials:  There are no special tools needed, simply some hand tools like screwdrivers, a drill, a saw and a soldering iron.  Powered tools would make things a little easier and speedier, and a workbench would be helpful too.  Materials are limited to plywood, plexiglass, solder and flux, caulking and copper wire.  You don’t make the solar cells – just get them very cheaply online.

Directions:  To build your own solar panel, you will need good quality step-by-step directions or instructions.  You will get advice on how to estimate the size and quantity of the panels, how to select and site the inverter, how to mount the panels and how to join the system to your domestic electric circuit.  

None of this is complicated, but investing in a good step-by-step assembly manual is, we believe, vital to ensure a safe and professional result.

We have reviewed several popular online manuals and have a favorite that will show you how to make a solar panel from scratch, with lots of diagrams, photos and even some very helpful videos.  It has full details about electrical wiring techniques and regulations, as well as how to feed any surplus electricity into your local utility company grid.

The final piece of good news is that it is possible to make a small solar panel, with a power output of about 100 watts, for under 200 dolars, including the cost of a good instruction manual and plans.  Building up several such panels to provide a very useful 1000 watts should cost less than 800 dollars.  Compare that with a readymade system, which will set you back several thousand dollars.

Makes sense to do it yourself, doesn’t it?