A lot, depends on the project and type of day I am having. Some projects work in thoughts but not in reality. Also, we usually add bloopers of the screw-ups. Some of the worst are when a project is good, great video and the tape or flash memory crashes. Has happened 3x in 5 years.
This guy cracks me up: "You just want a nice bead; That is the UGLIEST bead I've ever done..."/ clip to redemption bead video... VERY modest! Important for people to learn from. Good job brother! Keep posting!
Acrylic warps when many sheets are stacked one on top of the other in the sun and single sheets when placed on a dark surface in the sun. Look for cheap or free glass from yard sales or scrapped doors/windows. They are usually free, If a corner is chipped, the frame.
Hi, I liked your comment on the shading of the little bit of wood sticking up above the edge of the glass. You could minimize what little effect remains by chamfering that wood edge. You still have plenty of material to support the glazing, but it moves the shadow edge back that much farther. Every little bit helps. It also may help the surface shed water and debris.
Part 1 Dan, I've been watching these encapsulation videos for a while now, and it strikes me that we may have lost sight of what is actually necessary. Now, I've had solar cells laying around in my home and shop for years and I don't see them degrading or corroding nor do they seem to reduce noticeably in their output. It sure sounds like if I just hung large arrays of PVs in angled south-facing windows on some kind of mounting trellis that they would generate power and do just fine. See Part 2
Thank you for enjoying our videos:-) The glass is the front with a small air gap of cell to glass. Condensation can only form if there is enough air to water ratio when the cells are sealed. We are in FL with the most extreme humidity you will find and the air gap is so small no condensation. The one issue with some resins is heating from the sun on the front. If you use a less expensive resin, make sure it is a bit thicker. New video series on the way.
Just a word on applying sealant: If you cut the tip on an angle, put the cut side down in the corner, and push it forwards as you squeeze, and don't squeeze too much out as you go, it will make a very nice fillet.
If you use untempered glass, think about making the frame maybe a little larger, about 1/8" all the way around to allow for contraction during cold winter months. That could place a little too much pressure on one side or more and cause your glass to crack.
great job on the vids! right now i am paying about 20 cents per watt by buying solar cells with broken corners, i just got the cells, and they arent bad at all! most have just tiny cracks or small chips on the corners. most are whole and i just have to be REALLY CAREFUL with them!! totally worth it tho, and i have lots of glass lying around, also it can be had cheap. right now im looking at large picture frames at the local thrift shop so i dont have to build a frame. just seal it. touch and go
The most affordable option is found glass from windows or whatever. Then build to that size. You can cut if it is not tempered. Buying non-reflective glass runs the cost up close to a pre-manufactured completer panel. I have one made from a sliding glass door. Realllllly heavy but worked. I will have a new video using UV cure resins. They dimple horribly when cured but the plastic sheet method works good. watch?v=b_qQw0MsJ4I towards the end.
Hi Dan, I really learned allot from these 5 part series on DIY solar panel. Please clarify one thing for me. Is the clear epoxy you used in part 5 of these videos used to make front encapsulated panels. Would it make a difference if you used cheaper yellowing type epoxy on the back of the panel. I mean especially since you sealed the individual cells with strapping tape. I would imagine the strapping tape will keep any kind of epoxy clear or yellowing getting to the Sun side of the cells.
Thanks for all GREENPOWERSCIENCE . you have been done the great job . I have question for you today. since the solar cell produce 0.5v , mean that you will need 10 cells to have 5v. on some of my project i would like to use 2 or 3 or 4 cells of 0.5v each for my usb device., how can I do? do i have to use a DC to DC converter to boost up the voltage at 5v? thanks
Couldn't you use a tiny PC fan in the glass covered box to move moist air out vent holes in the panel so it doesn't condense on the glass or even use a wicking material?
Another great video dan, your eaerlier videos inspired me to make my first panel, mind you my 2 year old helped so it did not come out the best. Going to use some of your new videos for next time.
Dan, how long do your charged batteries last during the day if being charged and into the night when not? Amazing work you are doing here btw as your series is so easy to follow!
There seems to be some Dow clear RTV silicon that is marketed for this use. But I read some places it is somewhat water permiable, which makes it not as good. Also the price seems to be high ($35 to cover the backs of 36 3x6 cells). What is your thought? I still like the glass front idea.
Also please do consider using wooden dowel pins + clamps instead of that nasty screw from outside. That will make it even stronger cause the surface area of attachment will increase a lot, there can be no doubts about that!
@chicoarraes Pretty sure he means glass on solar side and resin on the backside. This prevents the resin going yellow effecting the voltage on the panel.
Hey Dan, what would you cover your panel with if you lived in a very hail prone area? I reside in North Texas and it's not uncommon to see, at the very least, golfball sized hail in the spring.
shower door glass seams to work fine for me.down't take the glass out of the frames,and use two by six framing around them,I got twenty eight of them to make some panels out of.
GREAT VIDEO THANKS.....QUESTION HOW GOOD IS SOLAR-TITE 384 SILICONE ELASTOMER SOLAR CELL ?HAVE YOU TRIED IT? IM PLANING TO USE IT ON MY SOLAR PANEL PROJECT......
Cutting wood always relieves some stresses, so it warps. If un-cured wood is cut, it warps more, so if you are using raw wood, use kiln dried, cut it 'close' to the dimensions, wait a little bit, for it to finish warping/relieving stresses (give it an hour or two), then cut it to final dimensions (it will warp a lot less).
Here's a little tip for people who use wood for their frames. You are better off buying either 2 x 8, 2 x 10, or 2 x 12 lumber for the frames and ripping them down to the desired size. The reason for this is that 2 x 4s and 2 x 6s are cut off of the outside of the log(tree) which is where all the branches are thus creating knots. The knots are what twist with variations in temperature and humidity levels which can break the glass. Very few knots if any in the larger lumber.
but aren't you gonna show how to encapsulate the panels in resin? is that off the menu because it yellows over time, or is is going to be both the resin and the glass? I'm curious for the next part.
If it is easily available in your area (and cheap) consider cypress rather than pine. (A friend got a lot of cypress cheap a few years ago, it would be great in this application.)
I am looking into doing something like this because I want to see if I can do it. If I fail, no big deal. Be honest, how many times did you mess up with this specific project and how many failures in all your DIY stuff have you had? My only experience with DIY is transferring computer parts into another case and metal class in high school. I know how to use spot welding and acetylene torches somewhat. by the way, it's a shame you dont have more viewers considering that solar power is important.
can Acrylic street be use or will they break down from the heat? looking for an cheapest street i could use(have little time but things like this keep you busy)
is there ANYTHING you can use to thin out resin (for spraying or brushing) without turning it white (clear resin i mean) i used 99% alcohol and it turned my clear resin white, and is there anything i can use to get urethane out of a brush
Victoria Perea UV resistant, no front encapsulation. If you use a resin that yellows and they are front encapsulated, then there will be a drop in power. About 30% drop for a full yellow if the wrong resin is used. If one cell gets blocked more than the others then the panel can suffer a big loss. Professionally made panels are becoming so inexpensive, that is usually the better way to go but DIY is still about 60% of the cost. Time is the issue or custom fits. If you have free glass from scrap or yard sales, it is worth it. The full DIY kits where you buy glass ext. costs more than a commercial panel.
Love the videos. I had watched one of your videos you had done on memory in acrylic. In it you moved a wire across the surface of the acrylic that was positioned a specific angle to the image to be transferred. I believe the wire was electrified somehow. Could you please tell me the name of this video please. Thanks for all of your wonderful videos! Peace!
can you make a home made anaerobic digester where you take waste food or farm wast to produce bio-gas methane for cooking and organic fertilizer for the garden. thank you for making these wonderful videos
Would be nice to see you do a D.I.Y. on the EVA-TVT encapsulant methods instead of the "Sylguard" style encapsulent. Other D.I.Y.'ers have found ways to do it without expensive lamination machines...
That is a piece of green wood that hasn't dried. It will warp I have seen multiple store bought panels with the aluminum frames screwed onto a larger wooden frame to mount on house warp and shatter all the panels.
The frames never warp. When the wood is ripped, any stress is reviled. A 2x4 that will ward does so at the saw. I have some untreated 10 years old and they are straight. I also made 2x4 windmill blades years ago, rain, sun, straight as the day they were cut. Picking a straight 2x4 is the trick. I use the cement floor at Lowes.
Great video. Thanks for making and uploading it. I'm learning a lot from your video series. :-) I can't believe anyone still uses imperial measurements though. It's so innacurate compared to metric. (I'm not having a go. btw.)
5:20 mosquito makes a pass by my right ear, I try to swat it away in confusion, and moments later I come to the conclusion that it must have been a digital mosquito cuz I have headphones on. lol
Part 2 So why do we bother with encapsulation, it seems to be the biggest problem with making solar panels? Why not merely suspend them against the inside of glass windows in a sealed wooden box with support from behind, and perhaps with dessicant silica packs inside that can be easily replaced every few months through a hatch, or else have it ventilated to the house air with pipes and a small fan? Then if you had failed cells you could replace them. So, why encapsulate at all? Makes no sense!
omg, this is the part I have waiting to see. Nobody as gone this far that I've seen in their videos as you have. Bravo! Very practical info.
A lot, depends on the project and type of day I am having. Some projects work in thoughts but not in reality. Also, we usually add bloopers of the screw-ups. Some of the worst are when a project is good, great video and the tape or flash memory crashes. Has happened 3x in 5 years.
This guy cracks me up: "You just want a nice bead; That is the UGLIEST bead I've ever done..."/ clip to redemption bead video... VERY modest! Important for people to learn from. Good job brother! Keep posting!
Treated wood is an option but usually curves when ripped. Dry pine with clear then white lasts forever without ground contact.
Acrylic warps when many sheets are stacked one on top of the other in the sun and single sheets when placed on a dark surface in the sun. Look for cheap or free glass from yard sales or scrapped doors/windows. They are usually free, If a corner is chipped, the frame.
Hi,
I liked your comment on the shading of the little bit of wood sticking up above the edge of the glass. You could minimize what little effect remains by chamfering that wood edge. You still have plenty of material to support the glazing, but it moves the shadow edge back that much farther. Every little bit helps. It also may help the surface shed water and debris.
Part 1 Dan, I've been watching these encapsulation videos for a while now, and it strikes me that we may have lost sight of what is actually necessary. Now, I've had solar cells laying around in my home and shop for years and I don't see them degrading or corroding nor do they seem to reduce noticeably in their output. It sure sounds like if I just hung large arrays of PVs in angled south-facing windows on some kind of mounting trellis that they would generate power and do just fine. See Part 2
Thank you for enjoying our videos:-)
The glass is the front with a small air gap of cell to glass. Condensation can only form if there is enough air to water ratio when the cells are sealed. We are in FL with the most extreme humidity you will find and the air gap is so small no condensation. The one issue with some resins is heating from the sun on the front. If you use a less expensive resin, make sure it is a bit thicker. New video series on the way.
I lived in arizona where it hails a lot and I also used Chicked wire to protect my power cells.. works great and didnt get damaged once!!!!
If you have frequent large hail, I would recommend a chicken wire screen. It only drops the watts by 1% if located 2 feet above the cells.
Just a word on applying sealant: If you cut the tip on an angle, put the cut side down in the corner, and push it forwards as you squeeze, and don't squeeze too much out as you go, it will make a very nice fillet.
Dan, Your videos relax me. Love when a new video is released.
If you use untempered glass, think about making the frame maybe a little larger, about 1/8" all the way around to allow for contraction during cold winter months. That could place a little too much pressure on one side or more and cause your glass to crack.
great job on the vids! right now i am paying about 20 cents per watt by buying solar cells with broken corners, i just got the cells, and they arent bad at all! most have just tiny cracks or small chips on the corners. most are whole and i just have to be REALLY CAREFUL with them!! totally worth it tho, and i have lots of glass lying around, also it can be had cheap. right now im looking at large picture frames at the local thrift shop so i dont have to build a frame. just seal it. touch and go
The most affordable option is found glass from windows or whatever. Then build to that size. You can cut if it is not tempered. Buying non-reflective glass runs the cost up close to a pre-manufactured completer panel. I have one made from a sliding glass door. Realllllly heavy but worked. I will have a new video using UV cure resins. They dimple horribly when cured but the plastic sheet method works good.
watch?v=b_qQw0MsJ4I
towards the end.
Hi Dan, I really learned allot from these 5 part series on DIY solar panel. Please clarify one thing for me. Is the clear epoxy you used in part 5 of these videos used to make front encapsulated panels. Would it make a difference if you used cheaper yellowing type epoxy on the back of the panel. I mean especially since you sealed the individual cells with strapping tape. I would imagine the strapping tape will keep any kind of epoxy clear or yellowing getting to the Sun side of the cells.
Thanks for all GREENPOWERSCIENCE . you have been done the great job . I have question for you today. since the solar cell produce 0.5v , mean that you will need 10 cells to have 5v. on some of my project i would like to use 2 or 3 or 4 cells of 0.5v each for my usb device., how can I do? do i have to use a DC to DC converter to boost up the voltage at 5v?
thanks
Have you tried spray it with transparent uv protection coating like the one used in the car's front lights? I believe it does the trick for a while.
Its excellent vedio, but can u tell me what 2 resins u used at the back of panels and how much do they cost.
watching you work is very relaxing.....
Couldn't you use a tiny PC fan in the glass covered box to move moist air out vent holes in the panel so it doesn't condense on the glass or even use a wicking material?
Another great video dan, your eaerlier videos inspired me to make my first panel, mind you my 2 year old helped so it did not come out the best. Going to use some of your new videos for next time.
This is amazing i was going to make mine with aluminum but i like the wood look & it will be easier to put together.
Dan, how long do your charged batteries last during the day if being charged and into the night when not?
Amazing work you are doing here btw as your series is so easy to follow!
There seems to be some Dow clear RTV silicon that is marketed for this use. But I read some places it is somewhat water permiable, which makes it not as good. Also the price seems to be high ($35 to cover the backs of 36 3x6 cells). What is your thought? I still like the glass front idea.
Also please do consider using wooden dowel pins + clamps instead of that nasty screw from outside. That will make it even stronger cause the surface area of attachment will increase a lot, there can be no doubts about that!
is there a web sight were all the items are listed? i am building a battery back-up/off grid power supply
@chicoarraes
Pretty sure he means glass on solar side and resin on the backside. This prevents the resin going yellow effecting the voltage on the panel.
Dan, I prefer to use a aluminum frame 1/8" thick for strength. Great ideas in your video.
Hey Dan, what would you cover your panel with if you lived in a very hail prone area? I reside in North Texas and it's not uncommon to see, at the very least, golfball sized hail in the spring.
shower door glass seams to work fine for me.down't take the glass out of the frames,and use two by six framing around them,I got twenty eight of them to make some panels out of.
can you use perspex or any other plastic material instead of glass?
GREAT VIDEO THANKS.....QUESTION HOW GOOD IS SOLAR-TITE 384 SILICONE ELASTOMER SOLAR CELL ?HAVE YOU TRIED IT? IM PLANING TO USE IT ON MY SOLAR PANEL PROJECT......
What about using EVA glass laminate or Spray Flex to encapsulate the solar cells?
Cutting wood always relieves some stresses, so it warps. If un-cured wood is cut, it warps more, so if you are using raw wood, use kiln dried, cut it 'close' to the dimensions, wait a little bit, for it to finish warping/relieving stresses (give it an hour or two), then cut it to final dimensions (it will warp a lot less).
Here's a little tip for people who use wood for their frames. You are better off buying either 2 x 8, 2 x 10, or 2 x 12 lumber for the frames and ripping them down to the desired size. The reason for this is that 2 x 4s and 2 x 6s are cut off of the outside of the log(tree) which is where all the branches are thus creating knots. The knots are what twist with variations in temperature and humidity levels which can break the glass. Very few knots if any in the larger lumber.
but aren't you gonna show how to encapsulate the panels in resin? is that off the menu because it yellows over time, or is is going to be both the resin and the glass? I'm curious for the next part.
If it is easily available in your area (and cheap) consider cypress rather than pine. (A friend got a lot of cypress cheap a few years ago, it would be great in this application.)
I am looking into doing something like this because I want to see if I can do it. If I fail, no big deal. Be honest, how many times did you mess up with this specific project and how many failures in all your DIY stuff have you had? My only experience with DIY is transferring computer parts into another case and metal class in high school. I know how to use spot welding and acetylene torches somewhat. by the way, it's a shame you dont have more viewers considering that solar power is important.
can Acrylic street be use or will they break down from the heat?
looking for an cheapest street i could use(have little time but things like this keep you busy)
Dan,
Dan, What kind of glass do you use in your home made panels? I just purchased a few hundred cells and want to make my own panels.
Dan have you considered buying a stock frame for this process?
Is there a list with all the materials needed to make the whole panel?
One more question : why did you use pine ? I think I will use treated wood .
Will just glass and epoxy stand up to hail storms?
What size glass do you recommend for best power output from the 36 cell solar panel that you used in the video?
Which Encapsulent Product do You Use, Is it still availabe, where do You Buy it ?
is there ANYTHING you can use to thin out resin (for spraying or brushing) without turning it white (clear resin i mean) i used 99% alcohol and it turned my clear resin white, and is there anything i can use to get urethane out of a brush
what is the name of the product you used??? where can i get it in Florida?
Any UL94Vx Epoxy resin is safe for solar panel application? (for example Sylgard184 - UL94V1)
will your panels stop working when the resin yellows? or will they just not generate as much power?
Victoria Perea UV resistant, no front encapsulation. If you use a resin that yellows and they are front encapsulated, then there will be a drop in power. About 30% drop for a full yellow if the wrong resin is used. If one cell gets blocked more than the others then the panel can suffer a big loss. Professionally made panels are becoming so inexpensive, that is usually the better way to go but DIY is still about 60% of the cost. Time is the issue or custom fits. If you have free glass from scrap or yard sales, it is worth it. The full DIY kits where you buy glass ext. costs more than a commercial panel.
@subscribeforcandy It works but requires very balances heat, heat guns work but can warp. I will cover it in a future video in this series.
do you use BPA as a hardening agent?
Do the have chlorine in them?
Love the videos. I had watched one of your videos you had done on memory in acrylic. In it you moved a wire across the surface of the acrylic that was positioned a specific angle to the image to be transferred. I believe the wire was electrified somehow. Could you please tell me the name of this video please.
Thanks for all of your wonderful videos!
Peace!
from what i have found you may want to use a vibrating table to get bubbles out.
what is the best resin you recommend for solar cells!?
Hello Sr.;
Can you spell to under stand the correct name of the clear glass?
Thanks in advance.
Dan,
Your Training...is it just high school shop class? Or a specialty school?
Hey Dan, thanks a for the videos, what brand of epoxy resin do you recommend of your backing?
Is it a good idea to us Lexan instad of glass
can you make a home made anaerobic digester where you take waste food or farm wast to produce bio-gas methane for cooking and organic fertilizer for the garden. thank you for making these wonderful videos
Would be nice to see you do a D.I.Y. on the EVA-TVT encapsulant methods instead of the "Sylguard" style encapsulent. Other D.I.Y.'ers have found ways to do it without expensive lamination machines...
Have you tried sylgard 184?
robert k Takes forever to cure. But good.
why cant you use 2 sheets of glass and water proof around it with resin?
You can use a back massager to get rid of the air!
Have you tried and silicone products?
what about the yellowing over time ?
Nice part about living in rural areas:-)
What glass is good?
Did you try polyurethane ?
Silicone the corners or it could leak. Thanks for sharing your time and making this video.
I found the best way is to use the good stuff for the first layer, and then buy the stuff that will yellow for a second coat.
Whats volts? Abbott and costello ref. Interesting stuff here.
@kondor1001 Do you want to spend $100 every 3-4 years for a new panel that can power one tv or do you want to spend $150 every 25 years?
ok. is it me, or is that saw blade mounted backwards?
How do I get free glass?
4:40 dan, please show us a video on how to build your teleportation machine, please. ;)
where's your push stick dan?
That is a piece of green wood that hasn't dried. It will warp I have seen multiple store bought panels with the aluminum frames screwed onto a larger wooden frame to mount on house warp and shatter all the panels.
The frames never warp. When the wood is ripped, any stress is reviled. A 2x4 that will ward does so at the saw. I have some untreated 10 years old and they are straight. I also made 2x4 windmill blades years ago, rain, sun, straight as the day they were cut. Picking a straight 2x4 is the trick. I use the cement floor at Lowes.
buying them flat must be the key
Great Videos Keep on the good work
Thanks.. But regrading the glue part, less is more and will actually make it stronger.
where's part 4?
Great video. Thanks for making and uploading it. I'm learning a lot from your video series. :-)
I can't believe anyone still uses imperial measurements though. It's so innacurate compared to metric. (I'm not having a go. btw.)
Why would you ever use wood for a solar panel frame though
low iron matte 1/4" tempered glass, its a bit expensive
5:20 mosquito makes a pass by my right ear, I try to swat it away in confusion, and moments later I come to the conclusion that it must have been a digital mosquito cuz I have headphones on. lol
I wish all my friends here in Africa had this information
I watched 1 thru 3, can't find 4 & 5. I see 6.
Try to use wireless mic.
umm , what about hail storms?
Transparent gold would be perfect ;-)
Part 2 So why do we bother with encapsulation, it seems to be the biggest problem with making solar panels? Why not merely suspend them against the inside of glass windows in a sealed wooden box with support from behind, and perhaps with dessicant silica packs inside that can be easily replaced every few months through a hatch, or else have it ventilated to the house air with pipes and a small fan? Then if you had failed cells you could replace them. So, why encapsulate at all? Makes no sense!
i found the video just took some looking around
Nope, otherwise you would launch the piece as soon as the wood gets touched.
Solar energy = star trek technology
if u are green, thumbs up
My shorts will yellow in time !!
Bottlewater glue FTW!!!!!
you have a cat? i think i heard it 12:27