First, draw a grid onto the plywood to represent the placement of your solar cells. You can customize your cells size and number for each number. After that, cut the plywood by using the circular saw to the appropriate size for your grid. This will be the base for your panel.
To form the frame for your panel, cut the 1 x 1-inch wood to appropriate lengths and attach it to the edges of the plywood using screws and caulk. In order to protect your panel from the elements, paint the completed wooden structure using outdoor paint.
Next on how to build your own solar panel is to join the cells in series. You can do this by soldering the tabs of your solar cells. Tabs from the back of one go into the back of the next in line. Take note that you need to take your time since the tabs are thin and fragile and this is delicate work.
Now, glue the solar cells onto the panel base in the grid patter you laid out earlier. Then attach the copper wire to be run to your electrical system and the blocking diode inline. The diode will prevent the batteries from discharging back out through the cells. The plexiglass should be secured over the top of the panel and must be sealed in place with caulk. Your solar panel is now complete and ready to use.