Building a solar panel is a fairly simple project, requiring some carpentry, soldering skills and patience. We will list several links to video's, pictures and step-by-step instructions.
Solar Panel Project Materials
solar cells - generally speaking, 36 cells will produce around 63 watts (maximum) of power via 18 volts DC at 3.5 amps. Several sites recommend purchasing cells which come with the tab wires soldered on already as this is a very tedious, time consuming job. These can be purchased off eBay for around $2 each. Note the cell size and therefore output, varies. Try to purchase cells that are all the same size
plywood or metal for the panel housing
glass or plexiglas for the panel top
pegboard to glue cells onto
silicone
solder, flux, wire
misc screws
DIY Solar Panel Assembly - Videos
We'll start with some how-to videos: this first video shows solar panels being assembled in a factory.
Next we have a series of 4 DIY videos (silent movies): part 1 - solder tabs to front of cells
Part 2 - solder tabs to back of cells
Part 3 - solder the cells into strings & solder strings together
Part 4 - shows the cells mounted, but does NOT show you how to mount them
DIY Home Solar Panels - Step-by-step Instructions
Mike Davis
Mike has built homemade solar panels and wind turbines for this off-grid get-away. His instructions and tips are very good. Personally, I think I would mount the cells a bit more securely. You also need to take his cost estimates with a grain of salt, as he gives everything he has on hand, a value of $0! A sheet of plexiglas is likely to cost you some money. So would the screws, wire and paint. I think it's fairly easy to see how a homemade solar panel could cost you over $3 per watt. If purchased in bulk, you can buy new solar panels for under $3 per watt on eBay and they come with a 25 year guarantee.
Tom from Otherpower provides lots of pictures with his instructions, plus there's the option to ask questions if you aren't clear on one of the steps. As mentioned at the start, this is a DIY project. You will learn lots about solar photovoltaic's by building these panels. There is a certain satisfaction from completing a project like this, and watching the lights come on from your own power source. However, these DIY project materials, will not last as long as production quality products. Enjoy, just the same.
The assembly instructions for this panel are a bit different - pull tabs through holes drilled in backing. However, something that is shared with all these sites, is the misleading cost. The author later confessed that the price he quoted for the cells, was several years old and no longer available. As well, the cost for all the wood and glass is set at $0, because he had it laying around. Just the same, the aluminum finish and glass cover, give this panel a more permanent feeling that the first to examples.