Assembling DIY Solar Panel Instructional Video

In the 5th video of the Green DIY Energy “Build your own solar panel for less than $100” series, you get to learn how to assembly your Do It Yourself (DIY) solar panel.

The most challenging part of making the solar module is already done. The tough part is to solder all the Photovoltaic cells together. Now that they are all joined together, it is time to connect the positive and negative home run wires to extract power from the cells.

Blocking Current Backflow

Many people do not know this. The solar panel creates current when exposed to sun light. The current can be used to charge a battery. What happens at night when there is no sun light?

As a matter of fact, current from the battery will actually flow back into the solar cells. This means, the PV cells is becoming an electric load that will drain power from the battery.

How do we overcome this problem? We use a simple [tag-tec]blocking diode[/tag-tec]. The blocking diode is to be installed on the positive home run wire.

The function of the diode is to block any backflow of current into the cells. It is a very useful little component that will maximizes your residential solar power system.

Here’s a tip. If you are using a charge controller to charge the battery, you do not need a blocking diode. The charge controller will do the function of the diode by maintaining a “one way street” for the current to flow.

Covering The Solar Cells

When it’s time to cover the solar cells in the solar panel, use a piece of clear Plexiglas. It is important for you to choose a Plexiglas that is UV proof.

Reason for this is because the panel will be exposed to sun light and UV ray most of the time. A normal Plexiglas will turn yellow after some time. The yellow surface will reduce the total amount of sun reaching the PV cells therefore reducing the power output.

When sealing the panel, make sure every joints are tight. You don’t want any moisture getting into the panel. If moisture caused by rain or show were to get into the panel, it will get trapped under the Plexiglas and affect the panel performance.

Using Screwdriver Instead Of The Drill

When you watch Bryan Clark, the host in the video installs the Plexiglas, you will see the right way of securing it to the panel.

He uses stainless stain screws. He drives the screws in initially with the drill but stop when the head of the screw is about to reach the Plexiglas.

The last couple of turn on the screws is recommended for you to use a screwdriver and crank it manually. This will give you a better feel and control of the screw. You don’t want the screw head to reach all the way into the Plexiglas or you will crack it.

If you want to know more on how to make your own solar panel for under $100, check out the Green DIY Energy program. For a comprehensive review of Green DIY Energy, go to

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2) Photovoltaic module – A photovoltaic module or photovoltaic panel is a packaged interconnected assembly of photovoltaic cells, also known as solar cells.

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