Cut Framing strips out of 1" x 2" x 8' Select Pine. You will need the following lengths:

• 2 ea - 45"
• 2 ea - 24"
• 1 ea - 20.5"

Drill Vent holes 2" from the top edge and 2" apart using an 11/64" drill bit. Do this on both ends. As you may notice from some of the pictures, this was an afterthought. I originally put these on the bottom edge and left a little gap between the wood and the aluminum frame. I had too much condensation build up, so I drilled these holes to resolve the issue. Since they are on the back and when in use, are off of the ground, this should not be an issue. Some folks recommend stuffing insulation in the holes to keep bugs, etc. out. I will likely do that at a later date.

Now is also a good time to drill an 11/64" hole in the side 3" from the top in the side of your frame for your wires to come through.

Soldering the cells together is tricky. For one, you cannot appy too much downward pressure to the cell or you will break it. The other hazard is tempurature. If your iron is too hot, you will burn up the pads on the cells. I used a standard tip and set the iron to 450 degrees fahrenheit. Apply flux to the pads and then take the wire coming from the front of the first cell and solder it to the back of the second. The bottom is positive and the top is negative. You will solder six cells together in series which will give you 3v. You'll need to do this six times so that you will have enough cells to generate 18v. Once you get to the end, you will need to attach wires to the bottom of the last cell so that you can connect each string to your bus wire. I used leftover wire from broken cells. I'll order a roll of the tabbing wire before I build my next panels.

It's a good idea to test each 3v string with a multi-meter as you complete them. This is the best time to do any rework, as it will be much more difficult later on in the process.

Once the paint is dry and all of your cells are soldered together you will need to adhere them to the insert. Use silicone to adhere them. Only use a spot in the center of the cell. As the wood expands and contracts with temperature, if you adhere on all edges or corners, the cells will fracture. Place the cells on the silicon and gently wiggle it to make sure it sticks.

Make sure you alternate your top and bottom wires so that when you connect them you are still alternating top to bottom.

Now you will want to work on the aluminum angle that will protect the edges of the acrylic. You'll need to cut the following lengths:

• 2 ea - 24"
• 2 ea - 37.5"

I cut mine with a dremel, and used a file to smooth out the rough edges.

Place the inserts into the enclosure and carefully screw them into place. Be careful, as one slip could damaga a cell.

Make sure that both sides are still alternating.