Gather solar cells, tabbing wire, bus wire, flux pen, solder, soldering iron, glass or clear acrylic, EVA or silicone encapsulant, backsheet, frame, junction box, and sealant
Plan the panel size, voltage, and current output
Arrange the solar cells in the desired series and parallel configuration
Clean the cells and work surface
Solder tabbing wire to the front contacts of each cell
Connect cells together with soldered tabbing wire
Attach bus wire to connect cell strings
Test electrical output of the connected cells
Place the cell assembly onto the glass or backing surface
Add encapsulant layers to secure the cells
Install the backsheet behind the cells
Seal the edges of the panel
Mount the frame around the panel
Install the junction box and connect output leads
Test voltage, current, and polarity
Place the panel in direct sunlight and verify performance
Use proper safety equipment while soldering and handling glass
Ensure all connections are insulated and weatherproof