Here are the materials and tools used :
- Wood saw
- Quick grip
- Powerful glue
- Cardboard to apply the glue
- Quite thin plywood
- Some planks to create the border
- Glass with aluminium frame
- Short and long screw
- Drill
- Titanium drill bit
- Silicone for outside conditions
- Vacuum
- Scissors
Of course you can choose better materials such as a custom plexiglass plate with an aluminum frame. In my case I prefer to reduce the monetary and environmental costs by recycling materials that are given to me free of charge or that I find on the street (there are super materials in the dumps absolutely everywhere in the city, is to have a luck, we really live in a world of plenty where everything is wasted).
We must build the box before continuing the welding. As the drill, the silicone, the cut wood and the glue can make debris, it is necessary to have the box ready to close very clean before placing the solar cells. After installing the cells, it becomes very fragile as long as it is not closed.
We glue the wood with a frame about 1 cm thick. The idea is to leave space for ventilation, cells, diodes and cables. In this project, it’s a bit ridiculous but my wood was cut too short, so I’ll innovate a bit … If the window is larger, plan a space in the middle to put a piece of wood to prevent the curved glass under the effect of weight.
Pressure is applied with sliding tongs and heavy objects at your fingertips. Ideally, spread glue over the contact.
Well, there is a hole, so we will fill it with the means of the edge: an old cardboard squeezed broken drawer!
It has dried, it’s time to screw the frame of the glass on the case. You have to use a $ 5 titanium wick, otherwise it breaks right away. If the wick is a bit too small in diameter, you can dig out the side to widen the hole (gently).
It is clear that the hole has been widened to let the screw head.
It’s holding! Make sure you clean everything to remove debris. It must be able to manipulate the glass and the rest follow (the screws must be deep enough in the wood).
