Define the purpose and power requirements
Choose the panel type and size
Gather solar cells, backing board, wiring, solder, flux, glass or clear cover, sealant, and junction box
Test and sort solar cells for matching output
Lay out the cells in rows and columns
Solder tabs to the front and back of each cell
Connect cells in series and parallel as needed
Attach the wired cell strings to the backing board
Connect the output leads to a junction box
Add bypass diodes if needed
Cover the cells with glass or a clear protective sheet
Seal all edges to protect against moisture
Mount the panel in a rigid frame
Test voltage and current output
Install the panel in a sunny location with proper tilt and orientation