A "handout" style page PDF version of this project is available with bigger pictures. Please contact us here and we'll send you a free copy.

We've also a great selection of ready made DIY Solar panel kits to get you started.

Learn how to design you own DIY solar power or lighting kit here

Wooden frame/box

The basic wooden box assembly before painting/treating with wood preserve

Painting the box

It's got to last a long time so make sure you slap it on!

Securing and painting the centre supports

The centre suppports help support the weight of the Aluminium sheet

Securing and painting the Corner supports

We screwed small triangle shaped pieces of wood into each corner to support the aluminium plate

Fitting the insulation

30mm Rockwool was placed behind the aluminium plate to insulate it so we don't loose any heat out the back of the panel

Absorber plate

Checking the aluminium absorber plate fits with 4mm gap for heat expansion

Lining the inside of the box with tin foil

The tin foil sits on top of the insulation and reflects heat back to the absorber plate which sits on top of the foil

Scratching the aluminium absorber

Roughing up and scratching the aluminium absorber plate so the paint adhears better to the aluminium

Marking and drilling

Marking and drilling the holes for fixing the copper snake

Snake bits!

Laying out and checing the copper snake parts ready for cleaning and soldering

More snake bits

All the corners and short pipe sections

DIY Solar power or lighting kit design

Learn how to design a solar power or solar lighting kit with our step by step guide. Like to know how big your batteries should be? Which charge controller should you use? How do you calculate solar panel size and power? Find the answers on these pages. 

Cleaning the snake bits

Make sure you clean the pipe ends thoroughly with the wire wool. The cleaner they are the better the joint and the less likely it is to fail

All soldered up

All soldered ready for a clean with a wire brush and testing

Seal one end ready for testing

Just to makes sure it's water tight under pressure especially before fitting the glass and painting it

Testing the snake

Attach mains water pressure and test for leaks for a couple of hours. Give it a bit of a bash and bend occasionally to stress.

Fitting the glazing strips

Fitting the glazing strips

Fitting the snake in the box

Cutting the sealed end so it will fit through the hole in the box

Securing the snake to the plate with the brackets

Securing the snake to the plate with the brackets

Pipe clips

After all the brackets/pipe clips have been put in place

Glazing

Testing the fit of the glass before painting the absorber plate

Painting

Painted with mat black metal paint before the glass was fitted

A DIY solar panel

We've a great selection of all the bits you'll need after you've constructed your panel. Have a look at the solar hot water accessories pages here.

A "handout" style page PDF version of this project is available with bigger pictures. Please contact us here and we'll send you a free copy.