DIY 100W Solar Panel: How to Build Homemade Solar Panels from Scratch – Part 2

As we left the previous video on how to
build a 100 watt solar panel now we're going to continue by preparing the solar
panel for the encapsulation the first step we need to do is by placing the
silicon on the edges of the glass this will prevents the resin from
spreading out of the panel epoxy resin is one of the best ways to
keep solar cells from a home made solar panel away from moisture for a panel of
this size you will need about 40 ounces about three pounds or one kilogram is
enough it's not cheap but it is the best choice over the eva film to encapsulate
a solar panel made at home to know where to get this type of clear epoxy resin
follow the links in video description below and of course epoxy hardener here
the blend should be two times the epoxy resin for one hardener and mix these two compounds in a plastic
container and mix it slowly mainly to avoid getting air into the mixture after about two minutes mixing the resin
with the hardener mix it again in another container to obtain a faster and
stronger curing finish this second mixture must be made to obtain a perfect
and well cured resin now what we have to do is to pour the
mixture on the back of the panel to do this simply pour the EPOC see resin from
top to bottom in a constant movement and after 12 hours you will have an
encapsulated solar panel now is time to make the panel frame get
three l-shaped aluminum profiles two meters long and at least three
millimeters thick you can also go with wood it all depends on your budget and
how much you want to spend with your panel this part can be done at the
beginning knowing the size of the glass the panel frame can be made and then
with the glass attached on the panel frame with silicone proceed with the
welding of the cells and the bass wires until finally the encapsulation is made
but always put the silicone in the edges of the glass before doing the
encapsulation now I'll leave you with the images on how to make the frame for
your panel measuring the length of each side of the glass mark each profile with
a marker leave at least two millimeters of cutting edge next to cut the profiles you can use a
cutter holder with a 90 degrees angle but it is best to use a miter saw an angular ruler can also be used to
check the cutting angle it is also useful to keep the profiles in place
during assembly and the best thing to attach the glass
and frame together as to use stainless steel brackets and screws for this panel
I use 12 brackets 8 to support the glass and 4 to join the profiles position the
brackets in place mark and drill the holes and now join each frame together as I mentioned earlier we can make the
frame before starting putting things together we can make the frame and
attach the glass with silicone then start soldiering the solar cells the bus
wire and in the end with the encapsulation so add the silicon to the
inner base of each profile then attach the glass to the frame next put the
brackets in place add the junction box and then the 100 watt solar panel it's
finally concluded so now we assemble a frame and the encapsulated panel
together and now we put the brackets in place but
if you decided to add a back sheet like this one on the back of your panel do it
before making the holes of the frame and then proceed by putting the brackets in
place Here I am NOT using the back sheet and the reason is for you to see how the
back of a solar panel looks like and now glue the junction box with the
same silicon paste make a hole to pass the pole wires and you have a solar
panel in your hands and now watch this next part
to see the voltage and amperage test thanks for watching and I'll see you
there

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