REALLY, REALLY CHEAP solar panel frames

[rstephan]

I just finished my first homemade solar panel. After purchasing the cells, and charge controller off eBay for less than 100 bucks, I realized that the cost of building the frame could exceed the cost of the cells and I was just basically building a window box.
I found a dual pane vinyl window for $5 at the Restore (that's the Habitat for Humanity's resale of donated and used building materials). I took it apart, removed the dual pane unit and cut the foam tape out from the bottom. I had mounted the cells on a piece acrylic sign plastic. The plastic sheet was then slid into the dual pane unit and resealed at the bottom. The unit was then reinstalled into the vinyl window frame.
Attached is a photo.

DSCN3657r.jpg

[Mike90250]

Congrats ! You were lucky to find stuff that would all fit together.

[Alan]

u still need to evacuate the oxygen from the panes or the cells oxidize. pump some inert gas in or pour some encapsulant in .

[rstephan]

oxygen

u still need to evacuate the oxygen from the panes or the cells oxidize. pump some inert gas in or pour some encapsulant in .

I have been thinking about that since I've heard that oxygen shortens the life of the cells. However, the application here is:

a) small shack in the boondocks
b) cheap homemade solar panel w/cheap charge controller
c) a few 6V deep cycle batteries
d) a little inverter

Benefit: no longer have to run little Honda "suitcase" generator at night to power 3 or 4 little twisty light bulbs for a few hours. If this works, then 5 years or so I'd upgrade to real panels, real inverter, and 6 or 8 batteries.

[Alan]

just paint the cells then

I'd still paint some clear coating over the cells then, you would need very little and it woudl really improve the life of the cells.

[rstephan]

Clear coat of cells.

What type of cheap clear would you recommend?

[Alan]

clear spray paint

well the cheapest would be some sort of clear coat spray paint, probably not gonna last 25 years, but heck of a lot better than nothin!

[shawnpc1]

I just finished my first homemade solar panel. After purchasing the cells, and charge controller off eBay for less than 100 bucks, I realized that the cost of building the frame could exceed the cost of the cells and I was just basically building a window box.
I found a dual pane vinyl window for $5 at the Restore (that's the Habitat for Humanity's resale of donated and used building materials). I took it apart, removed the dual pane unit and cut the foam tape out from the bottom. I had mounted the cells on a piece acrylic sign plastic. The plastic sheet was then slid into the dual pane unit and resealed at the bottom. The unit was then reinstalled into the vinyl window frame.
Attached is a photo.

[ATTACH=CONFIG]752[/ATTACH]

sounds great. im looking at doing somthing just like this

[carnini]

great find

What a great find. Makes me want to check the local place for something like that.

[cyberfast]

cheap frame

what i have done is use 2 poster frames 9 dollars each from walmart. put all the cells on the card board put the plastic on top and bottom assembled the frame and ran a small bead of silicon around the frame to water proof and seal it. i did spay a clear coat on the cell to. everything seams to be working so far.

[carnini]

First Build

Working on my first build myself, with the costs adding up when I put the frame, encapsulation, glass together but I figure if I really screw up I can always re-use things.

Did you leave the cardboard, isn't it permeable and going to let in mosture and rot out?

[cyberfast]

Working on my first build myself, with the costs adding up when I put the frame, encapsulation, glass together but I figure if I really screw up I can always re-use things.

Did you leave the cardboard, isn't it permeable and going to let in mosture and rot out?

thats why i used 2 poster frames so i could use the plastic from the other one to seal the back where the cardboard is. the silicon was used on both sides.

[carnini]

thats why i used 2 poster frames so i could use the plastic from the other one to seal the back where the cardboard is. the silicon was used on both sides.

Cool, missed the fact you had 2 poster frames. I like that idea and might try it on some left over cells. Wouldn't matter as much since for that price it is really cheap.

[cyberfast]

Working on my first build myself, with the costs adding up when I put the frame, encapsulation, glass together but I figure if I really screw up I can always re-use things.

Did you leave the cardboard, isn't it permeable and going to let in mosture and rot out?

Cool, missed the fact you had 2 poster frames. I like that idea and might try it on some left over cells. Wouldn't matter as much since for that price it is really cheap.

just a tip run the thick bus line for your + -(your outputs) longer then the frame so when you assemble the frame you can run the leads threw the back between the clear plastic and the outside frame (black part) the bus wire bends easily enough to squeeze between those two points.

[Mike90250]

mmmm.... cardboard, voltage, moisture..... You do realize that the plastic and the silicone seal is not water vapor proof, and will eventually, in a season or two, start fogging up with condensation .